Pipe, vehicle using the pipe, and method of manufacturing the pipe

Abstract

This application relates to a duct, a vehicle using the duct, and a method of manufacturing the duct. The duct includes an exoskeleton structure and a sound-absorbing structure disposed within and conforming to the exoskeleton structure. The exoskeleton structure provides external mechanical support to the sound-absorbing structure, thereby helping to maintain the tubular shape of the sound-absorbing structure. This external support does not interfere with airflow within the sound-absorbing structure. Furthermore, the external positioning of the exoskeleton structure allows for the integration of various support mounting features for installing the duct within the vehicle. In some examples, the exoskeleton structure includes multiple closed openings to reduce the weight of the exoskeleton structure and provide additional flexibility. Moreover, additive manufacturing of the exoskeleton structure allows for the realization of an integral structure with many of the features and properties described above.

Description

Technical Field

[0001] The present invention relates to a pipe comprising an exoskeleton structure and a sound-absorbing structure, and a vehicle using such a pipe. Background Technology

[0002] Many types of transportation, such as airplanes, utilize environmental control systems to supply treated air to passengers and / or cargo. For example, an environmental control system can supply air at a set temperature and / or a set flow rate to each passenger. Furthermore, it can remove particulate matter and other contaminants from incoming air before supplying clean air to its destination. Environmental control systems typically include various ducts to allow airflow through the vehicle. However, the airflow within these ducts generates noise, which can be undesirable, especially when these ducts are located near or within the passenger compartment. Various dedicated noise reduction components, such as zone silencers, have been used to reduce noise levels. However, these additional dedicated components increase the vehicle's weight, occupy additional space, and increase the overall system cost. Moreover, supporting the ducts within the vehicle typically requires additional components.

[0003] What is needed are new types of piping with on-site noise reduction capabilities that reduce and / or eliminate the need for additional noise reduction components. Furthermore, piping with reduced weight, more compact dimensions, and a high level of system modularity is required. Summary of the Invention

[0004] This paper describes noise attenuation ducts for environmental control systems and vehicles using these ducts. Methods for manufacturing these ducts are also provided. One type of duct includes an exoskeleton structure and a sound-absorbing structure disposed within and conforming to the exoskeleton structure. The exoskeleton structure provides external mechanical support for the sound-absorbing structure, thereby maintaining the tubular shape of the sound-absorbing structure. This external support does not interfere with airflow within the sound-absorbing structure. Furthermore, the external positioning of the exoskeleton structure provides options for integrating various support mounting features into the exoskeleton structure. These features are used to install the duct in a vehicle. This integration reduces the number of different components in the duct, reducing overall complexity and installation time. Specifically, additive manufacturing of the exoskeleton structure allows for this integration into a single monolithic structure and provides various features and properties described further below. In some examples, the exoskeleton structure includes multiple closed openings to reduce the weight of the exoskeleton structure and / or provide additional flexibility to the duct. Attached Figure Description

[0005] Figure 1The diagrams are based on some examples of aircraft including an environmental control system that utilizes ducts to supply treated air to various parts of the aircraft.

[0006] Figure 2A These are schematic cross-sectional views of pipes based on some examples, showing the various internal components and features of the pipes.

[0007] Figure 2B These are schematic perspective views of pipes based on some examples, showing the various external components and features of the pipes.

[0008] Figure 2C These are exploded cross-sectional views of pipes based on some examples, showing each component of the pipe.

[0009] Figure 2D , Figure 2E and Figure 2F The schematic cross-sectional views of some example pipes illustrate a variety of options for outer and inner membranes.

[0010] Figure 2G and Figure 2H These are schematic top views of pipes before and after a bend, based on some examples.

[0011] Figure 3A The diagram shows a schematic cross-sectional view of a pipe with an inner membrane fastener, based on some examples.

[0012] Figure 3B This is a schematic perspective view of a pipe section showing fasteners and axial limiters, based on some examples.

[0013] Figure 4A These are schematic perspective views of exoskeleton structures based on some examples, showing the closed openings of the exoskeleton structure as well as the fastening fasteners and axial limiters of the exoskeleton structure.

[0014] Figure 4B This is a schematic perspective view of another example of an exoskeleton structure configured to provide support to two separate parallel sound-absorbing structures and to form a fluid connection with one of these sound-absorbing structures via a ducted partition.

[0015] Figure 5A Based on some example pipe schematic cross-sectional views, it shows a connecting sleeve formed by an inner membrane and extending across the exoskeleton structure.

[0016] Figure 5B This is a schematic cross-sectional view of a pipe connected to another structure using a connecting sleeve, based on some examples.

[0017] Figure 6It is a process flow diagram based on some examples corresponding to the methods used to manufacture pipes.

[0018] Figures 7A to 7D It is based on some examples of the various stages during the manufacturing of pipelines.

[0019] Figure 8 This is a process flow diagram corresponding to the methods used in manufacturing and repairing aircraft.

[0020] Figure 9 A block diagram of an example aircraft is shown, based on some examples. Detailed Implementation

[0021] In the following description, numerous specific details are outlined to provide a thorough understanding of the proposed concepts. In some examples, the proposed concepts are practiced without some or all of these specific details. In other examples, well-known processing operations are not described in detail to avoid unnecessarily obscuring the described concepts. While some concepts will be described with specific examples, it will be understood that these examples are not intended to be limiting.

[0022] introduce

[0023] An environmental control system (ECS) can be used on a vehicle to control the temperature, humidity, and / or other environmental conditions inside the vehicle, such as the passenger compartment and cargo compartment. Figure 1 This is a schematic diagram of a vehicle 190 as an example of an aircraft. However, other types of vehicles are also within the scope of this disclosure. Vehicle 190 includes a compartment 192 for use by passengers and crew. Vehicle 190 also includes an ECS unit 194 for controlling environmental conditions within the compartment 192. Specifically, the ECS unit 194 is used to process, for example, air recirculated from the compartment 192 and / or obtained from the external environment. Some examples of this air processing include, but are not limited to, heating, cooling, filtering, humidity regulation, etc. In some examples, the ECS unit 194 is located away from the compartment 192, for example, in the wing area of ​​the aircraft, and is fluidly coupled to the compartment 192 via a duct system 196. This location of the ECS unit 194 allows for the utilization of other components and systems of the vehicle 190 (e.g., for power) and reduces the noise level within the compartment 192 during operation of the ECS unit 194.

[0024] refer to Figure 1 The duct system 196 extends from the ECS unit 194 to the compartment 192. The duct system 196 also extends through the compartment 192 to ensure the desired distribution of air within the compartment 192. For example, passengers can control this air distribution using individual vents connected to the duct system 196; for instance, each passenger may have a dedicated vent for controlling the flow of air from the duct system 196 to that passenger.

[0025] In some examples, the piping system 196 comprises, or more specifically, an assembly using multiple individual pipes 100. The individual pipes 100 are interconnected to form the piping system 196 and are also connected to various other components, such as the ECS unit 194, vents, etc. This modular approach facilitates the installation of the piping system 196. Furthermore, the same type of pipe 100 can be used for different parts of the piping system 196, or even for different vehicles. The pipes 100 are connected and supported by various structural components of the vehicle 190.

[0026] Duct 100 is specifically designed to provide noise attenuation as air flows from ECS unit 194 to compartment 192 via duct system 196. Therefore, duct 100 can also be referred to as a noise-attenuating duct. These noise attenuation characteristics are achieved through the specific structure of duct 100. For example, each duct includes an exoskeleton structure and a sound-absorbing structure, which is disposed within and conforms to the exoskeleton structure. The exoskeleton structure provides external mechanical support for the sound-absorbing structure, such as maintaining the tubular shape of the sound-absorbing structure. The sound-absorbing structure forms an outer shell for airflow through the duct and also provides overall noise attenuation due to the special design of the sound-absorbing structure.

[0027] In summary, the ductwork designs described herein provide an integrated additively manufactured exoskeleton structure coupled with a sound-absorbing structure (for insulation, noise attenuation / self-anesthesia). In some examples, the exoskeleton structure includes built-in (integrated / monolithic) support brackets. Depending on the aircraft size, construction, and design, these designs provide an average weight reduction of from about 5 kg to about 20 kg per aircraft, or more specifically from about 5 kg to about 10 kg. Furthermore, these ductwork designs reduce the total number of assembled parts by at least 50% or at least 55%, for example, by eliminating individual fasteners. In some examples, approximately 30 to 50 working hours are saved through these designs (partially achieved through additive manufacturing) and / or by using single-pass manufacturing and snap-on exoskeleton sleeves with integrated attachment features (e.g., push-in screws). Additionally, the moisture barrier has been moved from an internal location (in conventional ductwork) to an external location (e.g., as an outer membrane 130), thereby improving overall protection.

[0028] Pipe Example

[0029] Reference Figure 2A , Figure 2B and Figure 2CThe conduit 100 includes an exoskeleton structure 110 and a sound-absorbing structure 120. The exoskeleton structure 110 is formed using additive manufacturing, which allows for the integration of various features (described below) while maintaining the overall structure. The exoskeleton structure 110 includes an inner exoskeleton surface 112 having a tubular shape and defining an exoskeleton interior 114. The exoskeleton structure 110 also includes an outer exoskeleton surface 111 opposite the inner exoskeleton surface 112.

[0030] The sound-absorbing structure 120 is disposed within the exoskeleton interior 114 and conforms to the exoskeleton inner surface 112. The sound-absorbing structure 120 includes a sound-absorbing inner surface 122, which also has a tubular shape. The sound-absorbing inner surface 122 defines a sound-absorbing interior 124. The sound-absorbing structure 120 also includes a sound-absorbing outer surface 121 opposite to the sound-absorbing inner surface 122.

[0031] The exoskeleton structure 110 defines and supports the cross-sectional shape of the sound-absorbing structure 120. Examples of cross-sectional shapes include, but are not limited to, circular, elliptical, rectangular, square, triangular, or hexagonal cross-sections. Therefore, the sound-absorbing structure 120 does not need to be self-supporting, which allows for the use of a variety of novel materials in the sound-absorbing structure 120 and improves the sound absorption properties of the duct 100. For example, the sound-absorbing structure 120 may be formed from foam with a higher porosity than conventional ducts.

[0032] In some examples, the conduit 100 also includes an outer membrane 130 and / or an inner membrane 140. For example, Figure 2A A conduit 100 is shown having both an outer membrane 130 and an inner membrane 140. In this example, the sound-absorbing structure 120 can be completely enclosed by the outer membrane 130 and the inner membrane 140 (e.g., sealed from all environments by means of the outer membrane 130 and the inner membrane 140). Reference Figure 2B and Figure 2C The outer membrane 130 includes an inner outer membrane surface 132, which also has a tubular shape and defines an interior 134. The outer membrane 130 also includes an outer outer membrane surface 131 opposite to the inner outer membrane surface 132. When the outer membrane 130 is present, the inner outer membrane surface 132 is in contact with air flowing through the conduit 100. In other words, the inner outer membrane surface 132 defines the interior of the conduit 100. The inner outer membrane surface 132 at least partially contacts the sound-absorbing structure 120. The inner membrane 140 includes an inner inner membrane surface 142, which also has a tubular shape and defines an interior 144. The inner membrane 140 also includes an outer inner membrane surface 141 opposite to the inner inner membrane surface 142. When the inner membrane 140 is present, at least a portion of the outer inner membrane surface 141 contacts the sound-absorbing structure 120. In some examples (refer to below) Figure 5A and Figure 5B(Further description) An additional portion of the outer surface 141 of the inner membrane contacts or more specifically abuts against the inner surface 132 of the outer membrane to seal, for example, by sealing the sound-absorbing structure 120 between the outer membrane 130 and the inner membrane 140. The outer surface 131 of the outer membrane at least partially contacts the exoskeleton structure 110. In some examples, a portion of the outer surface 131 of the outer membrane is exposed, for example through an opening in the exoskeleton structure 110.

[0033] Figure 2D Another example is shown where the duct 100 has neither an outer membrane 130 nor an inner membrane 140. In this example, the sound-absorbing structure 120 is directly coupled to the exoskeleton structure 110. Furthermore, the sound-absorbing inner surface 122 of the sound-absorbing structure 120 is exposed to the air flowing within the duct 100. In other words, the sound-absorbing inner surface 122 forms the interior of the duct. This example can be used to reduce the overall weight of the duct 100, for example, when additional insulation of the sound-absorbing structure 120 (e.g., insulation from moisture) is not required.

[0034] Figure 2E Another example is shown in which the duct 100 includes an outer membrane 130 but not an inner membrane 140. In this example, the outer membrane 130 is disposed between the sound-absorbing structure 120 and the exoskeleton structure 110. The sound-absorbing inner surface 122 remains exposed to the air flowing within the duct 100 and forms the interior of the duct.

[0035] at last, Figure 2F Another example is shown in which the duct 100 includes an inner membrane 140 but not an outer membrane 130. In this example, the sound-absorbing structure 120 is directly coupled to the exoskeleton structure 110. However, the sound-absorbing inner surface 122 is protected from the influence of the air flowing within the duct 100. This example can help reduce friction of the air flowing within the duct 100.

[0036] In summary, in some examples, the sound-absorbing structure 120 is directly bonded to the inner surface 112 of the exoskeleton, for example, Figure 2D and Figure 2F As shown. Alternatively, one or more other components (e.g., outer membrane 130) may be provided between the exoskeleton structure 110 and the sound-absorbing structure 120, such as... Figure 2A and Figure 2E As shown. In either case, the exoskeleton structure 110 provides mechanical support for the sound-absorbing structure 120 and other components of the duct 100 (when these components are present, for example, the outer membrane 130 and / or the inner membrane 140).

[0037] In some examples, the exoskeleton structure 110 comprises thermoplastic polymers such as polyetherimide (PEI) and polyether ketone ketone (PEKK). Thermoplastic polymers can be used in additive manufacturing, which allows the formation of exoskeleton structures 110 with a variety of shapes and features, as will be described in more detail below. Furthermore, thermoplastic polymers can be welded together and formed into complex shapes using, for example, injection molding.

[0038] refer to Figure 2A and Figure 2B In some examples, the exoskeleton structure 110 includes a closed opening 116. The closed opening 116 serves to reduce the overall weight of the exoskeleton structure 110 while providing sufficient support for the sound-absorbing structure 120. Furthermore, the closed opening 116 can be used to increase the flexibility (e.g., bendability) of the exoskeleton structure 110 (and the entire conduit 100), for example, as... Figure 2G and Figure 2H As shown schematically. For example, the exoskeleton structure 110 is configured to allow the conduit 100 to bend about any axis perpendicular to the central axis 101.

[0039] In some examples, the area of ​​the closed opening 116 is larger than the area of ​​the inner surface 112 of the exoskeleton. In more specific examples, the ratio of the area of ​​the closed opening 116 to the area of ​​the inner surface 112 of the exoskeleton is at least about 2, at least about 4, or even at least about 10. As described above, this degree of closure of the opening 116 ensures weight reduction and flexibility.

[0040] In some examples, the closed openings 116 are uniformly distributed across the inner surface 112 of the exoskeleton. This uniform distribution of the closed openings 116 ensures uniform mechanical support and other properties of the exoskeleton structure 110. The closed openings 116 are separated by exoskeleton structural portions forming these openings. These exoskeleton structural portions provide support for the sound-absorbing structure 120.

[0041] In some examples, at least some of the closed openings 116 have a rhomboid shape. This shape allows for minimizing the size of the exoskeleton structure surrounding these closed openings 116 while providing uniform support for the sound-absorbing structure 120. Other shapes of the closed openings 116 (e.g., circular, square, hexagonal, and / or combinations thereof) are also within the range. In some examples, the main (maximum) dimensions of the closed openings 116 range from 5 mm to 100 mm, or more specifically from 10 mm to 50 mm, such as between 20 mm and 40 mm.

[0042] In the same or other examples, the diameter or more generally the main cross-sectional dimension of the sound-absorbing structure 120 is from 20 mm to 40 mm to 400 mm, or more specifically from 50 mm to 300 mm, such as from 100 mm to 200 mm. In the same or other examples, the length of the sound-absorbing structure 120 is from 0.5 m to 3 m, or more specifically from 0.75 m to 2 m, such as from 1 m to 1.5 m.

[0043] In some examples, the sound-absorbing structure 120 includes open-cell foam, such as melamine foam, polyimide foam, Kevlar, and other similar foams. The uncompressed thickness of the sound-absorbing structure 120 can be from 5 mm to 30 mm, or more specifically from 8 mm to 20 mm.

[0044] As described above, in some examples, the conduit 100 also includes an outer membrane 130 disposed between the exoskeleton structure 110 and the sound-absorbing structure 120. For example, the outer membrane 130 is in direct contact with the inner surface 112 of the exoskeleton and / or the sound-absorbing structure 120. The outer membrane 130 serves, for example, to protect the sound-absorbing structure 120 from the influence of the surrounding environment. As a result of this protection, a wider variety of sound-absorbing materials can be used in the sound-absorbing structure 120 as described above.

[0045] In some examples, the outer membrane 130 is formed of a polyether ketone ketone (PEKK) membrane, a polyether ether ketone (PEEK) membrane, a metallized polyether ether ketone (MPEEK) membrane, polyvinyl fluoride (PVF), a pressure-sensitive tape of a non-flammable material, or a combination thereof (e.g., a first PEKK membrane and a second PEEK membrane). In some examples, the outer membrane 130 includes an adhesive (e.g., a heat-activated adhesive) on a non-metallized inner surface facing the sound-absorbing structure 120 or on a non-metallized outer surface facing the exoskeleton structure 110. In some examples, the outer membrane 130 is formed of a high-quality fabric (such as a woven material with a high-quality resin). In the same or other examples, the thickness of the outer membrane 130 is from 0.005 mm to 1 mm, or more specifically from 0.050 mm to 0.5 mm.

[0046] In some examples, the conduit 100 also includes an inner membrane 140 disposed within the sound-absorbing interior 124. For example, the inner membrane 140 conforms to the sound-absorbing inner surface 122, or in a more specific example, directly contacts the sound-absorbing inner surface 122 of the sound-absorbing structure 120. The inner membrane 140 serves, for example, to protect the sound-absorbing structure 120 from the influence of air flowing through the conduit 100. For example, the air may contain some moisture. Furthermore, the inner membrane 140 provides a smooth inner surface that engages with the air.

[0047] In some examples, the inner membrane 140 is formed of a polyether ketone ketone (PEKK) membrane, a polyether ether ketone (PEEK) membrane, a metallized polyether ether ketone (MPEEK) membrane, polyvinyl fluoride (PVF), a pressure-sensitive tape of a non-flammable material, or a combination thereof (e.g., a first PEKK membrane and a second PEEK membrane). In some examples, the inner membrane 140 includes an adhesive (e.g., a heat-activated adhesive) on a non-metallized outer surface facing the sound-absorbing structure 120. In some examples, the inner membrane 140 is formed of a high-quality fabric (such as a woven material with a high-quality resin). In the same or other examples, the thickness of the inner membrane 140 is from 0.005 mm to 1 mm, or more specifically from 0.050 mm to 0.5 mm.

[0048] In some examples, the outer diaphragm 130 is sealed relative to the inner diaphragm 140, thereby isolating the sound-absorbing structure 120 from any environment. For example, the outer diaphragm 130 and the inner diaphragm 140 may be heat-sealed (e.g., heat-welded), adhered, or otherwise sealed. In a more specific example, the seal extends over the entire outer periphery of the sound-absorbing structure 120.

[0049] refer to Figure 3A In some examples, the conduit 100 also includes an inner membrane fastener 150. The inner membrane fastener 150 protrudes at least through the inner membrane 140 and supports the inner membrane 140 relative to the exoskeleton structure 110. The support of the inner membrane 140 also supports the sound-absorbing structure 120 relative to the exoskeleton structure 110. As described above, the sound-absorbing structure 120 is disposed between the inner membrane 140 and the exoskeleton structure 110. In some examples, the inner membrane fastener 150 protrudes through the sound-absorbing structure 120 and / or the outer membrane 130.

[0050] refer to Figure 3A In some examples, at least a portion of the endometrial fastener 150 is integral with the exoskeleton structure 110. This fastener integration allows for a minimization of the number of components required to assemble the conduit 100. For example, the endometrial fastener 150 may be a push pin inserted through the exoskeleton structure 110. In these examples, the exoskeleton structure 110 is equipped with a locking mechanism for receiving and retaining a portion of the push pin.

[0051] refer to Figure 3B In some examples, the exoskeleton structure 110 includes a fastening fastener 160 integral with the remainder of the exoskeleton structure 110. The fastening fastener 160 extends away from the sound-absorbing structure 120, or more specifically away from the central axis 101 of the conduit 100. The fastening fastener 160 is used to attach and support the conduit 100 to an external structure (such as...). Figure 3BOn the bracket 168 shown. For example, the fastener 160 protrudes at least partially through an opening in the bracket 168 and locks within that opening (e.g., using an interlocking feature). Integrating the fastener 160 into the exoskeleton structure 110 allows for a minimization of the number of parts required for the entire piping assembly.

[0052] refer to Figure 3B In some examples, the exoskeleton structure 110 includes an axial restraint 170, which is integral with the remainder of the exoskeleton structure 110. The axial restraint 170 is used to at least restrict the conduit 100 relative to an external structure (such as...). Figure 3B Axial movement of the bracket 168 shown (e.g., along the central axis 101 of the pipe 100). Integrating the axial limiter 170 into the exoskeleton structure 110 allows for a minimization of the number of parts required for the entire pipe assembly.

[0053] These and other aspects of the exoskeleton structure 110 are achieved through additive manufacturing of the exoskeleton structure 110. Figure 4A and Figure 4B Two examples of exoskeleton structures 110 formed by additive manufacturing are shown. Specifically, Figure 4A Examples and references above Figure 2B and Figure 3B The example shown and described is similar. In this example, the exoskeleton structure 110 includes a fastening fastener 160 and an axial limiter 170 (integral with the remainder of the exoskeleton structure 110). The exoskeleton structure 110 also includes a closed opening 116 having a diamond shape.

[0054] Figure 4B Another example of an exoskeleton structure 110 with different types of fastening fasteners 160 and different types of closed openings 116 is shown. Specifically, Figure 4B The exoskeleton structure 110 is configured to support two sound-absorbing structures that extend parallel to each other. The exoskeleton structure 110 includes two parts that can be integrated together or separated from each other. Figure 4B A portion of the exoskeleton structure 110 is also shown, which includes a duct segment 119 extending away from the central axis 101 of the portion. The duct segment 119 allows a portion of the airflow to be diverted to various components, such as vents, located along the length of the duct 100.

[0055] refer to Figure 5A In some examples, a portion of the inner diaphragm 140 extends beyond the sound-absorbing structure 120 to form a connecting sleeve 145. The connecting sleeve 145 can be used to connect to other components of the same ECS system, such as other pipes, vents, etc. Figure 5BThe connection to component 500 is schematically shown. For example, component 500 includes an annular protrusion 510 such that the connecting sleeve 145 extends over and beyond the annular protrusion 510. The entire assembly also includes an annular clamp 520 that forces a portion of the connecting sleeve 145 against component 500. Figure 5B As shown, this portion of the connecting sleeve 145 extends over the annular protrusion 510.

[0056] In some examples, a portion of the outer membrane 130 extends beyond the sound-absorbing structure 120. This portion may also form a connecting sleeve 145 similar to the connecting sleeve 145 of the inner membrane 140 described above. Furthermore, in some examples, this portion of the outer membrane 130 seals against a similar extension of the inner membrane 140, for example, as... Figure 5A As shown.

[0057] Pipe manufacturing example

[0058] Figure 6 A process flow diagram corresponding to method 600 for manufacturing pipe 100 is shown. Various examples of pipe 100 have been described above. In some examples, method 600 includes block 610: manufacturing exoskeleton structure 110 using additive manufacturing. Exoskeleton structure 110 includes an exoskeleton inner surface 112 having a tubular shape and defining an exoskeleton interior 114. Additive manufacturing allows various features to be integrated into exoskeleton structure 110. For example, these features and other parts of exoskeleton structure 110 can be integral (e.g., a single continuous piece without any connecting joints). Alternatively, exoskeleton structure 110 includes multiple pieces joined together by hinges and / or fasteners to facilitate additive manufacturing and allow for the formation of particularly long exoskeleton structures 110.

[0059] Alternatively, the exoskeleton structure 110 is injection molded. For example, the exoskeleton structure 110 comprises two mating halves (e.g., separated along a plane containing the central axis of the exoskeleton structure 110). The two halves are fastened together around a sound-absorbing structure 120, which is formed into a sound-absorbing tubular shape prior to the fastening operation.

[0060] In some examples, method 600 includes block 615: sealing the sound-absorbing structure 120 between the outer membrane 130 and the inner membrane 140. This operation is performed, for example, before the sound-absorbing structure 120 is formed into a sound-absorbing tubular shape, as further described below. Figure 7A A sub-assembly is shown that forms during this operation and includes a sound-absorbing structure 120 sealed between the outer membrane 130 and the inner membrane 140. In some examples, the sub-assembly is substantially planar after the operation is completed.

[0061] In some examples, method 600 includes block 620: forming the sound-absorbing structure 120 into a sound-absorbing tubular shape, for example as... Figure 7B As shown schematically. In a more specific example, the frame 620 that forms the sound-absorbing structure 120 into a sound-absorbing tubular shape includes a frame 622: the sound-absorbing sheet is wound on a mandrel having a sound-absorbing tubular shape.

[0062] In some examples, method 600 includes block 630: inserting the sound-absorbing structure 120 into the exoskeleton interior 114 such that the sound-absorbing structure 120 conforms to the exoskeleton interior surface 112, for example as... Figure 7C As shown schematically. In a more specific example, the mandrel used to form the sound-absorbing tubular shape can be held inside the sound-absorbing structure 120 during this operation.

[0063] In some examples, method 600 includes block 640: securing the sound-absorbing structure 120 to the exoskeleton structure 110 such that the sound-absorbing structure 120 maintains its sound-absorbing tubular shape. For example, an inner membrane fastener 150 is used for this operation, such as... Figure 7D As shown schematically.

[0064] Airplane example

[0065] In some examples, the methods and systems described above are used in aircraft, and more generally in the aerospace industry. Specifically, these methods and systems can be used during aircraft manufacturing as well as during aircraft repair and maintenance.

[0066] Therefore, the devices and methods described above can be applied to, for example... Figure 8 The aircraft manufacturing and maintenance method 900 shown, and as such Figure 9 The aircraft 902 is shown. During pre-production, method 900 includes the specification and design 904 of the aircraft 902 and the procurement of materials 906. During production, the manufacturing of parts and sub-assemblies of the aircraft 902 and system integration 910 are carried out. Subsequently, the aircraft 902 is certified and delivered 912 for service 914. When in customer use, routine maintenance and repairs 916 are scheduled for the aircraft 902, which also includes modifications, reconfigurations, refurbishments, etc.

[0067] In some examples, each of the processes in Method 900 is performed or implemented by a systems integrator, a third party, and / or an operator (e.g., a customer). For this description, systems integrators include, but are not limited to, any number of aircraft manufacturers and main systems subcontractors; third parties include, but are not limited to, any number of vendors, subcontractors, and suppliers; and operators can be airlines, leasing companies, military entities, service organizations, etc.

[0068] like Figure 9As shown, the aircraft 902 produced by method 900 includes a fuselage 918 having multiple systems 920 and an interior 922. The fuselage 918 includes the wings of the aircraft 902. Examples of systems 920 include one or more of the following: a propulsion system 924, an electrical system 926, a hydraulic system 928, and an environmental system 930, or more specifically, an ECS system including one or more sound attenuation ducts described above. Any number of other systems may be included.

[0069] The apparatus and methods proposed herein may be employed during any one or more stages of method 900. For example, the component or sub-assembly corresponding to manufacturing 908 may be manufactured or processed in a manner similar to that of the component or sub-assembly produced when aircraft 902 enters service. Moreover, during manufacturing 908 and system integration 910, one or more apparatus examples, method examples, or combinations thereof may be used, for example, to significantly accelerate the assembly of aircraft 902 or reduce the cost of the aircraft. Similarly, when aircraft 902 enters service, one or more apparatus examples, method examples, or combinations thereof may be utilized, for example, but not limited to maintenance and repair 916.

[0070] Other examples

[0071] In addition, this specification includes examples based on the following terms:

[0072] Clause 1. A conduit comprising:

[0073] An exoskeleton structure formed using additive manufacturing and including an inner surface of the exoskeleton having a tubular shape and defining the interior of the exoskeleton; and

[0074] A sound-absorbing structure disposed inside the exoskeleton and conforming to the inner surface of the exoskeleton, the sound-absorbing structure including a sound-absorbing inner surface defining the sound-absorbing interior.

[0075] Clause 2. The conduit according to Clause 1 further includes an outer membrane disposed between the exoskeleton structure and the sound-absorbing structure, such that the outer membrane is in direct contact with the inner surface of the exoskeleton.

[0076] Clause 3. The conduit according to Clause 2, wherein the outer membrane is in direct contact with the exoskeleton structure.

[0077] Clause 4. The conduit according to Clause 1 further includes an inner membrane disposed within the sound-absorbing interior and conforming to the inner surface of the sound-absorbing interior.

[0078] Clause 5. The conduit according to Clause 4 further includes an outer membrane disposed between the exoskeleton structure and the sound-absorbing structure, such that the outer membrane is in direct contact with the inner surface of the exoskeleton.

[0079] Clause 6. The pipes pursuant to Clause 5, wherein the outer membrane is sealed relative to the inner membrane, thereby isolating the sound-absorbing structure from the environment.

[0080] Clause 7. The conduit according to Clause 6, wherein a portion of the inner diaphragm extends over the sound-absorbing structure to form a connecting sleeve.

[0081] Clause 8. The conduit pursuant to Clause 5, wherein at least one of the inner or outer membrane comprises a polyether ketone ketone (PEKK) membrane, a polyether ether ketone (PEEK) membrane, polyvinyl fluoride (PVF), a pressure-sensitive tape of a non-flammable material, or a combination thereof.

[0082] Clause 9. The conduit pursuant to Clause 5 further includes an inner diaphragm fastener, wherein:

[0083] The inner membrane fasteners protrude through the inner membrane and the sound-absorbing structure; and

[0084] The inner membrane fasteners support the inner membrane and sound-absorbing structure relative to the exoskeleton structure.

[0085] Clause 10. The conduit pursuant to Clause 9, wherein at least a portion of the inner membrane fastener is integral with the exoskeleton structure.

[0086] Clause 11. The conduit pursuant to Clause 9 further includes an outer membrane, wherein:

[0087] The inner membrane fasteners also protrude through the outer membrane; and

[0088] The inner membrane fasteners support the outer membrane relative to the exoskeleton structure.

[0089] Clause 12. The conduit according to any one of Clauses 1 to 11, wherein the exoskeleton structure comprises a thermoplastic polymer.

[0090] Clause 13. The conduit according to any one of Clauses 1 to 12, wherein the exoskeleton structure includes a plurality of closed openings evenly distributed around the inner surface of the exoskeleton.

[0091] Clause 14. A pipe according to Clause 13, wherein at least some of the plurality of closed openings have a diamond shape.

[0092] Clause 15. The conduit pursuant to Clause 13, wherein the area of ​​the plurality of closed openings is greater than the area of ​​the inner surface of the exoskeleton.

[0093] Clause 16. The conduit pursuant to Clause 13, wherein the area of ​​the plurality of closed openings is at least twice the area of ​​the inner surface of the exoskeleton.

[0094] Clause 17. A conduit according to any one of Clauses 1 to 16, wherein the exoskeleton structure includes a fastening fastener integral with the remainder of the exoskeleton structure and extending away from the sound-absorbing structure, the fastening fastener being used to attach and support the conduit to the external structure.

[0095] Clause 18. The conduit according to Clause 17, wherein the exoskeleton structure includes an axial limiter integral with the remainder of the exoskeleton structure and for at least limiting axial movement of the conduit relative to the external structure.

[0096] Clause 19. A pipeline pursuant to any of Clauses 1 to 18, wherein:

[0097] The tubular shape is defined by the central axis of the pipe;

[0098] The exoskeleton structure is constructed with a cross-section perpendicular to the central axis, maintaining a tubular shape; and

[0099] The exoskeleton structure is also configured to provide conduits that bend around any axis perpendicular to the central axis.

[0100] Clause 20. A pipe according to any one of Clauses 1 to 19, wherein the tubular shape has at least one of a circular cross-section, an elliptical cross-section, a rectangular cross-section, a square cross-section, a triangular cross-section, or a hexagonal cross-section.

[0101] Clause 21. A pipeline pursuant to any one of Clauses 1 to 20, wherein:

[0102] The tubular shape is defined by the central axis of the pipe; and

[0103] The exoskeleton structure includes tubular sections extending away from the central axis.

[0104] Clause 22. A pipe pursuant to any of Clauses 1 to 21, wherein the sound-absorbing structure comprises melamine foam.

[0105] Article 23. A means of transport comprising:

[0106] An environmental control system includes piping, wherein the piping includes:

[0107] An exoskeleton structure formed using additive manufacturing and including an inner surface of the exoskeleton having a tubular shape and defining the interior of the exoskeleton; and

[0108] A sound-absorbing structure disposed inside the exoskeleton and conforming to the inner surface of the exoskeleton, the sound-absorbing structure including a sound-absorbing inner surface defining the sound-absorbing interior.

[0109] Clause 24. Means of transport pursuant to Clause 23, wherein the means of transport is an airplane.

[0110] Clause 25. A method of manufacturing a pipe, the method comprising:

[0111] Additive manufacturing is used to fabricate an exoskeleton structure, which includes an exoskeleton inner surface having an exoskeleton tubular shape and defining the interior of the exoskeleton.

[0112] The sound-absorbing structure is formed into a sound-absorbing tubular shape that complements the tubular shape of the exoskeleton;

[0113] The sound-absorbing structure is inserted into the exoskeleton so that it conforms to the inner surface of the exoskeleton; and

[0114] The sound-absorbing structure is fixed to the exoskeleton structure, so that the sound-absorbing structure maintains the sound-absorbing tubular shape.

[0115] Clause 26. The method according to Clause 25, wherein forming the sound-absorbing structure into a sound-absorbing tubular shape comprises: rolling the sound-absorbing sheet onto a mandrel having a sound-absorbing tubular shape.

[0116] Clause 27. The method according to Clause 25 further includes sealing the sound-absorbing structure between the outer membrane and the inner membrane before forming the sound-absorbing structure into a sound-absorbing tubular shape.

[0117] in conclusion

[0118] Although the foregoing concepts have been described in detail for clarity, it will be apparent that certain changes and modifications can be implemented within the scope of the appended terms. It should be noted that many alternative implementation processes, systems, and devices exist. Therefore, this example is to be considered illustrative rather than restrictive.

Claims

1. A pipe (100), wherein The pipeline includes: Exoskeleton structure (110), the exoskeleton structure being integrally formed using additive manufacturing and including an exoskeleton inner surface (112), the exoskeleton inner surface (112) having a tubular shape and defining the interior of the exoskeleton (114); and A sound-absorbing structure (120) is disposed inside the exoskeleton (114) and conforms to the inner surface (112) of the exoskeleton, the sound-absorbing structure (120) including a sound-absorbing inner surface (122) defining a sound-absorbing interior (124). The exoskeleton structure (110) provides external mechanical support for the sound-absorbing structure (120) to maintain the tubular shape of the sound-absorbing structure; and the exoskeleton structure includes a plurality of closed openings (116) evenly distributed around the inner surface (112) of the exoskeleton, and the area of ​​the plurality of closed openings (116) is larger than the area of ​​the inner surface (112) of the exoskeleton.

2. The pipe (100) according to claim 1 further includes an outer membrane (130), the outer membrane being disposed between the exoskeleton structure (110) and the sound-absorbing structure (120), such that the outer membrane (130) is in direct contact with the inner surface (112) of the exoskeleton.

3. The pipe (100) according to claim 2, wherein, The outer membrane (130) is in direct contact with the exoskeleton structure (110).

4. The pipe (100) according to any one of claims 1 to 3 further includes an inner membrane (140) disposed within the sound-absorbing interior (124) and conforming to the sound-absorbing inner surface (122).

5. The pipe (100) according to claim 4 further includes an outer membrane (130), the outer membrane being disposed between the exoskeleton structure (110) and the sound-absorbing structure (120), such that the outer membrane (130) is in direct contact with the inner surface (112) of the exoskeleton.

6. The conduit (100) according to claim 4 further includes an outer membrane (130), the outer membrane being disposed between the exoskeleton structure (110) and the sound-absorbing structure (120), such that the outer membrane (130) is in direct contact with the inner surface (112) of the exoskeleton, wherein, The outer membrane (130) is sealed relative to the inner membrane (140), thereby isolating the sound-absorbing structure (120) from the environment.

7. The pipe (100) according to claim 5 further includes an inner membrane fastener (150), wherein: The inner membrane fastener (150) protrudes through the inner membrane (140) and the sound-absorbing structure (120); and The inner membrane fastener (150) supports the inner membrane (140) and the sound-absorbing structure (120) relative to the exoskeleton structure (110).

8. The pipe (100) according to claim 1, wherein, At least some of the plurality of closed openings (116) have a rhomboid shape.

9. A means of transport (190), comprising: An environmental control system, the environmental control system including a conduit (100), wherein the conduit (100) includes: Exoskeleton structure (110), the exoskeleton structure being integrally formed using additive manufacturing and including an exoskeleton inner surface (112), the exoskeleton inner surface (112) having a tubular shape and defining the interior of the exoskeleton (114); and A sound-absorbing structure (120) is disposed inside the exoskeleton (114) and conforms to the inner surface (112) of the exoskeleton, the sound-absorbing structure (120) including a sound-absorbing inner surface (122) defining a sound-absorbing interior (124). The exoskeleton structure (110) provides external mechanical support for the sound-absorbing structure (120) to maintain the tubular shape of the sound-absorbing structure; and the exoskeleton structure includes a plurality of closed openings (116) evenly distributed around the inner surface (112) of the exoskeleton, and the area of ​​the plurality of closed openings (116) is larger than the area of ​​the inner surface (112) of the exoskeleton.

10. The means of transport (190) according to claim 9, wherein, The means of transport (190) is an airplane.

11. A method (600) for manufacturing a pipe (100), wherein, The method (600) includes: The exoskeleton structure (110) is manufactured in one piece using additive manufacturing, the exoskeleton structure (110) including an exoskeleton inner surface (112) having an exoskeleton tubular shape and defining the interior of the exoskeleton (114). The sound-absorbing structure (120) is formed into a sound-absorbing tubular shape that complements the tubular shape of the exoskeleton; The sound-absorbing structure (120) is inserted into the interior (114) of the exoskeleton, such that the sound-absorbing structure (120) conforms to the inner surface (112) of the exoskeleton; and The sound-absorbing structure (120) is fixed to the exoskeleton structure (110) such that the exoskeleton structure (110) provides external mechanical support for the sound-absorbing structure (120) to maintain the tubular shape of the sound-absorbing structure. The exoskeleton structure includes a plurality of closed openings (116) evenly distributed around the inner surface (112) of the exoskeleton, and the area of ​​the plurality of closed openings (116) is greater than the area of ​​the inner surface (112) of the exoskeleton.

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