Solid adhesive film and method for acoustic lining

Abstract

A system and method for bonding a panel and an acoustic screen of an acoustic liner together using a solid adhesive film having a first adhesive surface opposite to a second adhesive surface. The system includes a solid adhesive film having a first adhesive surface opposite to a second adhesive surface; an acoustic screen bonded to the first adhesive surface of the solid adhesive film; and a panel bonded to the second adhesive surface of the solid adhesive film. The method includes bonding the panel to the first adhesive surface of the solid adhesive film and bonding the acoustic screen to the second adhesive surface of the solid adhesive film.

Description

[0001] Federally Funded Research

[0002] This disclosure was made with government support under Contract No. DTFAWA-15-A-80013 awarded by the Federal Aviation Administration (FAA) of the U.S. Department of Transportation. The government has certain rights in this disclosure. Technical Field

[0003] The present subject matter generally relates to acoustic liners including acoustic screens and panels and methods for bonding the acoustic screens and panels. Background Art

[0004] Acoustic liners can be used to damp or attenuate sound waves. For example, acoustic liners are used to damp or attenuate noise from turbines (such as turbofan engines) and noise from other devices (such as wind turbine blades).

[0005] An exemplary acoustic liner includes an acoustic core positioned between a perforated or otherwise porous acoustic screen and a substantially non-porous backing plate. The acoustic core may include a plurality of resonant cells. The perforated or otherwise porous acoustic screen allows sound waves to enter the acoustic core and to exit in a manner that dampens or attenuates the sound waves.

[0006] The acoustic shield is attached to the panel. Conventional methods of attaching these components include liquid films and spray adhesives. However, these adhesives liquefy and wick into the acoustic shield when heated to cure, thereby becoming debris that blocks the holes formed in the acoustic shield and the panel, affecting airflow through the holes. Further, liquid spray adhesives provide a lower level of adhesion between the acoustic shield and the panel. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] A full and effective disclosure of the present disclosure, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0008] Figure 1A A perspective, partially cut-away view of an exemplary turbine having an acoustic liner according to an exemplary embodiment of the present disclosure is schematically depicted.

[0009] Figure 1B An aircraft equipped with a turbine having an acoustic liner according to an exemplary embodiment of the present disclosure is schematically depicted.

[0010] Figure 2 Schematically depicted isometric partial cross-sectional view of a portion of an exemplary acoustic liner according to an exemplary embodiment of the present disclosure.

[0011] Figure 3A is a schematic diagram of steps in a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to an exemplary embodiment of the present disclosure.

[0012] Figure 3B is a schematic diagram of steps in a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to an exemplary embodiment of the present disclosure.

[0013] Figure 3C is a schematic diagram of steps in a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to an exemplary embodiment of the present disclosure.

[0014] Figure 3D is a schematic diagram of steps in a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to an exemplary embodiment of the present disclosure.

[0015] Figure 3E is a schematic diagram of steps in a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to an exemplary embodiment of the present disclosure.

[0016] Figure 3F is a schematic diagram of steps in a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to an exemplary embodiment of the present disclosure.

[0017] Figure 3G is a schematic diagram of steps in a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to an exemplary embodiment of the present disclosure.

[0018] Figure 3H is a schematic diagram of steps in a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to an exemplary embodiment of the present disclosure.

[0019] Figure 4A is a schematic diagram of steps of a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to another exemplary embodiment of the present disclosure.

[0020] Figure 4B is a schematic diagram of steps of a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to another exemplary embodiment of the present disclosure.

[0021] Figure 4C is a schematic diagram of steps of a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to another exemplary embodiment of the present disclosure.

[0022] Figure 4D is a schematic diagram of steps of a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to another exemplary embodiment of the present disclosure.

[0023] Figure 4E is a schematic diagram of steps of a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to another exemplary embodiment of the present disclosure.

[0024] Figure 5 Depicted is a top view of a solid adhesive film having perforations according to an exemplary embodiment of the present disclosure.

[0025] Fig. 6A is a flow chart of a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to an exemplary aspect of the present disclosure.

[0026] Figure 6B is a flow chart of a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to another exemplary aspect of the present disclosure.

[0027] Fig. 7A is a flow chart of a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to another exemplary aspect of the present disclosure.

[0028] Figure 7B is a flow chart of a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to another exemplary aspect of the present disclosure.

[0029] Fig. 8A is a flow chart of a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to another exemplary aspect of the present disclosure.

[0030] Figure 8B is a flow chart of a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to another exemplary aspect of the present disclosure.

[0031] Fig. 9A is a flow chart of a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to another exemplary aspect of the present disclosure.

[0032] Fig. 9B is a flow chart of a method of bonding an acoustic screen to a panel of an acoustic liner using a solid adhesive film according to another exemplary aspect of the present disclosure.

[0033] Fig.10 is a schematic diagram of an acoustic liner according to an exemplary embodiment of the present disclosure.

[0034] Fig.11 is a schematic diagram of an acoustic liner according to another exemplary embodiment of the present disclosure.

[0035] Fig.12 is a flow chart of a method for bonding panels of an acoustic liner using a solid adhesive film having a first adhesive surface opposite a second adhesive surface according to the present disclosure.

[0036] Corresponding reference characters indicate corresponding parts throughout the several views.The examples listed herein illustrate exemplary embodiments of the present disclosure, and these examples should not be construed as limiting the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0037] Reference will now be made in detail to the present embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter references to refer to features in the drawings. Like or similar reference numbers in the drawings and description have been used to refer to like or similar parts of the present disclosure.

[0038] The following description is provided to enable those skilled in the art to make and use the embodiments contemplated for implementing the present disclosure. However, various modifications, equivalents, variations, and substitutes will be apparent to those skilled in the art. Any and all such modifications, variations, equivalents, and substitutes are intended to fall within the scope of the present disclosure.

[0039] For purposes of the description hereinafter, the terms "upper," "lower," "right," "left," "vertical," "horizontal," "top," "bottom," "lateral," "longitudinal," and their derivatives shall relate to the present disclosure as it is oriented in the accompanying drawings. However, it shall be understood that the present disclosure may employ various alternative variations unless expressly specified to the contrary. It shall also be understood that the specific devices shown in the accompanying drawings and described in the following specification are merely exemplary embodiments of the present disclosure. Accordingly, specific dimensions and other physical characteristics associated with the embodiments disclosed herein shall not be considered limiting.

[0040] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another, and are not intended to indicate the position or importance of each component.

[0041] The terms "upstream" and "downstream" refer to the relative directions of the flow of a fluid in a fluid path. For example, "upstream" refers to the direction from which the fluid is flowing, and "downstream" refers to the direction to which the fluid is flowing.

[0042] The terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attachment as well as indirect coupling, fixing, or attachment through one or more intermediate components or features, unless otherwise indicated herein.

[0043] The singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.

[0044] Approximate language, as used throughout the specification and claims, is applied to modify any quantitative representation that can be permissibly varied without resulting in a change in the basic function to which it is related. Thus, a value modified by one or more terms such as "approximately," "roughly," and "substantially" is not limited to the precise value specified. In at least some cases, the approximate language may correspond to the precision of an instrument used to measure the value, or the precision of a method or machine used to construct or manufacture a component and / or system. For example, the approximate language may refer to within a margin of 10%.

[0045] Here and throughout the specification and claims, range limitations are combined and interchanged, and unless context or language dictates otherwise, such ranges are identified and include all sub-ranges contained therein. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

[0046] Advanced acoustic linings typically require low resistance panels with a high percentage of open area where the acoustic screen is bonded to the panel.

[0047] As described above, conventional methods of attaching these components include liquid films and spray adhesives. However, when heated and cured, these adhesives liquefy and wick into the acoustic shield, thereby becoming debris that clogs the multiple holes formed in the acoustic shield and the panel, affecting airflow through the holes. Further, liquid spray adhesives provide a lower level of adhesion between the acoustic shield and the panel. The systems and methods of the present disclosure, which use a solid adhesive film, solve these challenges of conventional methods with hole clogging caused by the flow of adhesive liquid. In addition, the systems and methods of the present disclosure ensure alignment of the solid adhesive film and the panel during the bonding process, such as alignment of the perforations of the component. The solid adhesive film of the present disclosure allows the acoustic shield to be bonded to the perforated panel in the acoustic liner.

[0048] Exemplary embodiments of the present disclosure will now be described in more detail. Figure 1A As shown, one or more acoustic liners 100 may provide a system for damping or attenuating sound waves, including sound waves associated with turbine 102. Figure 1B In the exemplary embodiment shown, an aircraft 140 may include a turbine 102 (e.g., a turbofan engine) having one or more acoustic liners 100 configured to attenuate noise from the turbine 102. In other exemplary embodiments, it is contemplated that a wind turbine may include turbine blades with one or more acoustic liners 100 applied to one or more portions of the turbine blades to attenuate noise therefrom. Figure 1A As shown, the turbine 102 defines an axial direction A (extending parallel to a longitudinal axial centerline 118 for reference), a radial direction R, and a circumferential direction C (extending about the axial direction A).

[0049] Still reference Figure 1A , the turbine 102 may include a casing or nacelle 104 surrounding a turbine 106 and / or a fan rotor 108, the fan rotor 108 including a plurality of circumferentially spaced fan blades 110 powered by the turbine 106. The exemplary casing or nacelle 104 includes an inlet 112 and a duct having a duct wall 114 that generally directs an airflow 116 downstream through the fan rotor 108 along a longitudinal axial centerline 118. One or more acoustic liners 100 provide a system for damping or attenuating sound waves. An exemplary system may include one or more acoustic liners 100 annularly disposed along the duct wall 114. The one or more acoustic liners 100 may have a location along the duct wall 114 that is upstream of the fan blades 110. The one or more acoustic liners 100 may also be positioned downstream of the fan blades 110. For example, the one or more acoustic liners 100 may be positioned at or behind the inner barrel 120 portion of the nacelle 104. Additionally or alternatively, one or more acoustic liners 100 may be positioned at or behind a fan housing portion 122 and / or a transcowl portion 124 of the nacelle 104. In some embodiments, the turbine 102 may include a plurality of housings 104 surrounding the turbine 106. In some embodiments, the plurality of housings 104 may be configured and arranged annularly relative to each other. Each such housing 104 may include an inner duct wall and an outer duct wall. One or more acoustic liners 100 may be positioned around the inner duct wall and / or outer duct wall of any one or more of the plurality of housings 104. In addition, one or more acoustic liners 100 may be positioned near a non-rotating portion of the fan housing portion 122 or other components of the turbine 102. These locations include ducts or housings within the turbine 102, where one or more acoustic liners 100 may be used for noise suppression (e.g., damping or attenuation) at various frequency ranges, including within a range of frequency ranges. For example, one or more acoustic liners 100 may be positioned at the core cover portion 126. Those skilled in the art will appreciate further areas in which one or more acoustic liners 100 may be positioned to dampen or attenuate noise generated or emitted by various aspects of the turbine 102 , all of which are within the scope of the present disclosure.

[0050] In operation, the turbine 102 generates excessive noise. To illustrate an exemplary source of turbine noise, it should be understood that the fan rotor 108 rotates within the fan housing portion 122, generating discrete tonal noise primarily at the blade passing frequency (BPF) and multiples thereof, as well as broadband noise over a wide frequency range. During takeoff of the aircraft 140, the fan blades 110 may reach transonic and supersonic rotational speeds, generating noise that propagates from the duct defined by the duct wall 114 into the surrounding environment. In an exemplary embodiment, one or more acoustic liners 100 are configured and arranged to suppress the noise resonating at the BPF and the harmonics of the BPF and the main broadband noise components from the fan. One or more acoustic liners 100 or various portions thereof may be configured to damp or attenuate sound waves, thereby reducing sound at a specific frequency or within a certain frequency range. Some aspects of one or more acoustic liners 100 may be configured to reflect or propagate incident sound waves multiple times before the sound waves escape from the one or more acoustic liners 100. These multiple reflections may reduce the amplitude of the sound waves. Additionally, aspects of one or more acoustic liners 100 may be configured to cause the sound waves to become out of phase due to such reflection or propagation. When the sound waves become out of phase, portions of the sound waves tend to cancel each other, thereby reducing at least some of the energy in the sound waves.

[0051] Figure 2 An isometric partial cutaway view of a portion of an exemplary acoustic liner 100 is shown. Figure 2 The acoustic liner 100 shown may be configured with Figure 1A The acoustic liner 100 may be used together with the turbine 102 shown to attenuate noise from any other source considered within the scope of those skilled in the art. In some embodiments, the acoustic liner 100 may be disposed in the airflow 116 (also in the Figure 1A-1B The acoustic liner 100 may be provided by flanges or by contact with the duct wall 114 and / or the fan housing portion 122 ( Figure 1A ) and is fixed within the turbine 102 by other attachments. The acoustic liner 100 includes an acoustic core 200 located between the acoustic shield 202 and a substantially non-porous backing plate 204. The acoustic shield 202 may include a perforated plate, a mesh (e.g., formed of wire, cloth, fiber and / or filaments), or a combination thereof. Additionally or alternatively, the acoustic shield 202 may include an additively manufactured component. In some embodiments, the acoustic shield 202 and the backing plate 204 form planes having a substantially parallel orientation relative to each other. The acoustic core 200 is composed of a hollow honeycomb structure or resonant unit 206 disposed between the acoustic shield 202 and the backing plate 204. The resonant unit 206 includes a plurality of unit walls that define a hollow resonant space 208.

[0052] In an exemplary embodiment, the acoustic core 200, the acoustic shield 202, and / or the backing plate 204 may be formed using additive manufacturing techniques, which may allow the acoustic liner 100 to have novel configurations, geometries, and / or features over previous acoustic liners that provide certain improvements and / or avoid certain disadvantages. Such additive manufacturing techniques may be used alone or in conjunction with other manufacturing techniques to provide an acoustic liner 100 according to the present disclosure.

[0053] For example, the acoustic liner 100 may be formed in whole or in part using additive manufacturing techniques. Sequential layers of the acoustic core 200, the acoustic shield 202, and / or the backing plate 204 may be additively manufactured using suitable additive manufacturing techniques.

[0054] The acoustic core 200, the acoustic shield 202, and the backing plate 204 may be formed as part of an additive manufacturing technique or any other suitable process, either separately or simultaneously with one another. The acoustic shield 202 and / or the backing plate 204 may additionally or alternatively be formed as part of any other manufacturing technique, either separately or simultaneously with the acoustic core 200. Additionally or alternatively, the acoustic shield 202 and / or the backing plate 204 may be bonded to the acoustic core 200, for example, using a bonding process such as a thermal, sonic, or electrical welding process.

[0055] In addition, reference will now be made to Figure 3A-5 The systems and methods of the present disclosure are described for more effectively bonding an acoustic shield 202 to a panel of an acoustic liner 100 .

[0056] Reference now Figures 3A-4E , showing a method for bonding an acoustic shield 306, 406 to an acoustic liner 100 ( Figure 1A and 2 ) of panels 308, 408 and methods.

[0057] As mentioned above, advanced acoustic liners typically require low resistance panels with a high percentage of open area, with the acoustic screen bonded to the panel.

[0058] As described above, conventional methods of attaching these components include liquid films and spray adhesives. However, these adhesives liquefy and wick into the sound shield when heated and cured, thereby becoming debris that clogs the multiple holes formed in the sound shield and the panel, affecting the airflow through the holes. In addition, liquid spray adhesives provide a lower level of adhesion between the sound shield and the panel. The systems and methods of the present disclosure using solid adhesive films solve these challenges of conventional methods with hole clogging caused by the flow of adhesive liquid. In addition, the systems and methods of the present disclosure ensure the alignment of the solid adhesive film and the panel during the bonding process, such as the alignment of the perforations of the component. The solid adhesive film of the present invention allows the sound shield to be bonded to the perforated panel in the acoustic liner.

[0059] refer to Figures 3A-3HIn an exemplary embodiment of the present disclosure, a method of attaching an acoustic shield 306 ( Figure 3G ) bonded to the acoustic liner 100 ( Figure 1A and 2 ) of panel 308.

[0060] It is conceivable that the solid adhesive film 300 used with the present disclosure does not allow liquid to flow therethrough and does not exhibit liquid flow. As used herein, the term "solid adhesive film" may refer to an adhesive that does not include any liquid adhesive and does not allow any liquid to flow through the solid adhesive film and / or other components. In this way, the solid adhesive film of the present disclosure does not allow wicking to other components, such as the sound screen 306 and / or the panel 308, during the bonding process, and does not cause inadvertent clogging of any perforations of the sound screen 306 and / or the panel 308. In other words, the solid adhesive film of the present disclosure prevents clogging of the perforations of the components during the bonding process, thereby resulting in a more solid, consistent panel 308 resistance in the sound liner 100.

[0061] It is contemplated that the solid adhesive film 300 of the present disclosure has a temperature capability of up to 300 degrees Fahrenheit. In other exemplary embodiments, it is contemplated that the solid adhesive film 300 of the present disclosure has other temperature capabilities, such as up to 350 degrees Fahrenheit and / or up to 400 degrees Fahrenheit. In addition, the solid adhesive film 300 of the present disclosure has improved peel strength and improved toughness, such as the ability of the solid adhesive film 300 to absorb energy and plastic deformation without breaking. In this way, the solid adhesive film 300 increases the impact resistance to other components (e.g., panel 308) to reduce impact damage to the components.

[0062] It is contemplated that the solid adhesive film 300 of the present disclosure includes a double-sided adhesive, such as a pressure-sensitive adhesive on both sides. In addition, the solid adhesive film 300 is a compliant and / or elastic adhesive, such as an elastic band. For example, in an exemplary embodiment, it is contemplated that the solid adhesive film 300 includes foam or rubber, with pressure-sensitive adhesive on both sides. It is also contemplated that the solid adhesive film 300 does not allow liquid to flow therethrough, as described above.

[0063] The solid adhesive film 300 and / or the panel 308 may be provided in a variety of different embodiments before bonding. For example, they may already contain a plurality of perforations (aligned with the perforations on the acoustic screen 306), may initially be substantially free of any perforations, or a combination thereof. Depending on the state of the initial solid adhesive film 300 and / or the panel 308, various possible steps may be included, for example, perforating one or more of the solid adhesive film 300 and the panel 308, or aligning the solid adhesive film 300 and the panel 308 using existing perforations. Although various examples of various optional steps are presented herein for various possible embodiments (e.g., with or without pre-existing perforations), it should be understood that these are non-limiting examples and alternative embodiments may be further implemented within the scope of the present disclosure.

[0064] Bonding the acoustic shield 306 to the panel 308 using the disclosed system and method including the solid adhesive film 300 also allows for more consistent manufacturing of the acoustic liner 100 to eliminate hole clogging and maintain acoustic benefits. The disclosed system and method also reduces manufacturing cycle time.

[0065] Reference Figures 3A-3C , sound lining 100( Figure 1A and 2 ) includes a solid adhesive film 300, the solid adhesive film 300 includes a first adhesive face 302 and a second adhesive face 304. In the illustrated embodiment, the solid adhesive film 300 does not include perforations and the panel 308 has no perforations, and the panel 308 is bonded to the first adhesive face 302 or the second adhesive face 304 of the solid adhesive film 300.

[0066] refer to Figure 3A and 3B In a first step, the method includes bonding a panel 308 to a first bonding face 302 of a solid bonding film 300. Importantly, Figure 3B As shown, at this step, neither the solid adhesive film 300 nor the panel 308 has perforations.

[0067] Next, refer to Figure 3C , the method includes machining perforations through the panel 308 and the solid adhesive film 300. In an exemplary embodiment, a machining tool 310 having one or more cutting elements 312 is used to simultaneously machine the perforations through the panel 308 and the solid adhesive film 300 in a single machining step. It is contemplated that the machining tool 310 may include laser cutting, die punching, lathe, sandblasting, drill press, blasting, or any other cutting machining process. The controlled machining perforations through the panel 308 and the solid adhesive film 300 of the present disclosure toughen the panel 308 and improve the mechanics of the panel 308.

[0068] Still reference Figure 3CIn one exemplary embodiment, the step of machining perforations through the panel 308 and the solid adhesive film 300 includes making perforations through the solid adhesive film 300 and then through the panel 308. For example, one or more cutting elements 312 are positioned adjacent to the solid adhesive film 300 and perforate the solid adhesive film 300 first before perforating the panel 308.

[0069] refer to Figure 3D In another exemplary embodiment, the step of machining perforations through the panel 308 and the solid adhesive film 300 includes making perforations through the panel 308 and then through the solid adhesive film 300. For example, one or more cutting elements 312 are positioned adjacent to the panel 308 and perforate the panel 308 first before perforating the solid adhesive film 300.

[0070] refer to Figure 3E and 3F In some exemplary embodiments, a solid adhesive film 300 having a first adhesive surface 302 and a second adhesive surface 304 is used to bond an acoustic shield 306 to a panel 308 of an acoustic liner 100 ( Figure 1A and 2 ) can also include removing the backing material 320 from the first bonding side 302 and the second bonding side 304 of the solid bonding film 300 before the bonding step. It is also contemplated that the backing material 320 provides further support for the solid bonding film 300 to support and strengthen the solid bonding film 300 during the bonding and machining steps. It is contemplated that the backing material 320 can include a rigid support material, such as a wet-laid composite material or other rigid support material. Figure 3F In one exemplary embodiment, with the backing material 320 on the solid adhesive film 300, a machining tool 310 having one or more cutting elements 312 is used to machine the perforations through the panel 308, the solid adhesive film 300, and the backing material 320. In another exemplary embodiment, with the backing material 320 removed from the solid adhesive film 300, a machining tool 310 having one or more cutting elements 312 is used to machine the perforations through the panel 308 and the solid adhesive film 300.

[0071] refer to Figure 5 , after the step of machining the perforations through the panel 308 and the solid adhesive film 300, the panel 308 and the solid adhesive film 300 will have the appropriate configuration of perforations 390 therethrough.

[0072] refer to Figure 3GNext, after the step of machining the perforations through the panel 308 and the solid adhesive film 300, the method includes bonding the acoustic shield 306 to the second adhesive face 304 of the solid adhesive film 300. It is contemplated that in other embodiments, the acoustic shield 306 may be bonded to the solid adhesive film 300 at other times, such as before the step of machining the perforations through the panel 308 and the solid adhesive film 300.

[0073] In the first bonding surface 302 and / or the second bonding surface 304 ( Figure 3E and 3F ) in an exemplary embodiment of a solid adhesive film 300 having a backing material 320 thereon, the backing material 320 is removed prior to bonding the acoustic shield 306 to the second adhesive face 304 of the adhesive 300.

[0074] refer to Figure 3H In an exemplary embodiment, the solid adhesive film 300 includes a first protective release film or paper 322 on the first adhesive face 302 of the solid adhesive film 300 and a second protective release film or paper 324 on the second adhesive face 304 of the solid adhesive film 300 .

[0075] refer to Figures 4A-4E In another exemplary embodiment of the present disclosure, a method of attaching an acoustic shield 406 ( Figure 4D ) bonded to the acoustic liner 100 ( Figure 1A and 2 ) of panel 408.

[0076] As described above with reference to the solid adhesive film 300, it is conceivable that the solid adhesive film 400 used with the present disclosure does not allow liquid to flow therethrough and does not exhibit liquid flow. As used herein, the term "solid adhesive film" may refer to an adhesive that does not include any liquid adhesive and does not allow any liquid to flow through the solid adhesive film and / or other components. In this way, the solid adhesive film of the present disclosure does not allow wicking into other components, such as the sound screen 406 and / or the panel 408, during the bonding process, and does not cause inadvertent clogging of any perforations of the sound screen 406 and / or the panel 408. In other words, the solid adhesive film of the present disclosure prevents clogging of the perforations of the components during the bonding process, thereby resulting in a more solid, consistent panel resistance in the sound liner 100.

[0077] refer to Figure 4A In a first step, the method comprises perforating the solid adhesive film 400 and perforating the panel 408. In this way, the solid adhesive film 400 and the panel 408 comprise one or more perforations 490.

[0078] In an exemplary embodiment, a machining tool 410 having one or more cutting elements 412 is used to machine the perforations through the solid adhesive film 400 and the panel 408 in a single machining step. In an exemplary embodiment, the machining tool 410 comprises a laser cutter. It is contemplated that the machining tool 410 may comprise a die, a lathe, a sandblast, a drill press, a blasting or any other cutting machining process. The controlled machining of the perforations through the panel 408 and the solid adhesive film 400 of the present disclosure toughens the panel 408 and improves the mechanics of the panel 408.

[0079] It is contemplated that in some exemplary embodiments, the machining tool 410 or other process can simultaneously perforate the solid adhesive film 400 and the panel 408. However, it is also contemplated that in other exemplary embodiments, the machining tool 410 or other process can perforate the solid adhesive film 400 and the panel 408 separately.

[0080] 4B, the method includes using an alignment tool 416 to align and bond the panel 408 to the first bonding face 402 of the solid adhesive film 400. It is contemplated that the alignment tool 416 may be any tool that allows the panel 408 to be aligned and bonded to the solid adhesive film 400.

[0081] Still reference Figure 4B In an exemplary embodiment, the step of aligning and bonding the panel 408 to the first bonding surface 402 of the solid adhesive film 400 using the alignment tool 416 includes placing the solid adhesive film 400 in the alignment tool 416 and then pressing the alignment tool 416 with the solid adhesive film 400 onto the panel 408 to bond the panel 408 to the first bonding surface 402 of the solid adhesive film 400.

[0082] In an exemplary embodiment, alignment tool 416 includes one or more protrusions 418 that are positionable within one or more cooperating perforations 490 of solid adhesive film 400 to properly align solid adhesive film 400 within alignment tool 416 .

[0083] refer to Figure 4C In another exemplary embodiment, the step of aligning and bonding the panel 408 to the first bonding surface 402 of the solid adhesive film 400 using the alignment tool 416 includes placing the panel 408 in the alignment tool 416 and then pressing the alignment tool 416 with the panel 408 onto the solid adhesive film 400 to bond the panel 408 to the first bonding surface 402 of the solid adhesive film 400.

[0084] In the exemplary embodiment, alignment tool 416 includes a protrusion 418 that may be positioned within perforations 490 of panel 408 to properly align panel 408 within alignment tool 416 .

[0085] refer to Figure 4D , after aligning and bonding the panel 408 to the first bonding side 402 of the solid bonding film 400 using the alignment tool 416, the method further includes bonding the acoustic shield 406 to the second bonding side 404 of the solid bonding film 400. It is contemplated that in other embodiments, the acoustic shield 406 may be bonded to the solid bonding film 400 at other times, for example, before aligning and bonding the panel 408 to the first bonding side 402 of the solid bonding film 400 using the alignment tool 416.

[0086] refer to Figure 4E In an exemplary embodiment, the solid adhesive film 400 includes a first protective release film or paper 422 on the first adhesive face 402 of the solid adhesive film 400 and a second protective release film or paper 424 on the second adhesive face 404 of the solid adhesive film 400. In such an exemplary embodiment, the first protective release film 422 and the second protective release film 424 are removed before bonding the solid adhesive film 400 and the panel 408.

[0087] Reference now Figures 6A-7B , the method for bonding the acoustic screen to the acoustic liner 100 (using a solid adhesive film) will now be discussed. Figure 1A and 2 ) of the panel. These methods also correspond to the above reference Figures 3A-3H The system and method are described in detail.

[0088] for Fig. 6A In an exemplary aspect, method 600 generally includes bonding an unperforated first solid adhesive film to an unperforated panel at (602); attaching a backing material to the first solid adhesive film at (604); machining through the panel and the first solid adhesive film with the backing material at (606); removing the backing material at (608); applying a second solid adhesive film to the other side of the panel at (610); perforating the second solid adhesive film using hot air at (612); removing a second release film / paper from the first solid adhesive film at (614); bonding an acoustic screen to the first solid adhesive film at (616); and bonding an acoustic core to the second solid adhesive film at (618).

[0089] for Figure 6BIn an exemplary aspect, method 650 generally includes bonding an unperforated first solid adhesive film to an unperforated panel at (652); attaching a backing material to the first solid adhesive film at (654); machining through the panel and the first solid adhesive film with the backing material at (656); removing the backing material at (658); applying a second solid adhesive film to the other side of the panel at (660); perforating the second solid adhesive film using hot air at (662); bonding an acoustic core to the second solid adhesive film at (664); removing a second release film / paper from the first solid adhesive film at (666); and bonding an acoustic screen to the first solid adhesive film at (668).

[0090] for Fig. 7A In an exemplary aspect of the method 700, the method 700 generally includes bonding an unperforated first solid adhesive film to an unperforated panel at (702); machining through the first solid adhesive film having a backing material and the panel at (704); applying a second solid adhesive film to the other side of the panel at (706); perforating the second solid adhesive film using hot air at (708); removing a second release film / paper from the first solid adhesive film at (710); bonding an acoustic screen to the first solid adhesive film at (712); and bonding an acoustic core to the second solid adhesive film at (714).

[0091] for Figure 7B In an exemplary aspect, method 750 generally includes bonding an unperforated first solid adhesive film to an unperforated panel at (752); machining through the first solid adhesive film having a backing material and the panel at (754); applying a second solid adhesive film to the other side of the panel at (756); perforating the second solid adhesive film using hot air at (758); bonding an acoustic core to the second solid adhesive film at (760); removing a second release film / paper from the first solid adhesive film at (762); and bonding an acoustic screen to the first solid adhesive film at (764).

[0092] Reference now Figures 8A-9B The use of a solid adhesive film to bond the acoustic screen to the acoustic liner 100 ( Figure 1A and 2 ) of the panel. These methods also correspond to the above reference Figures 4A-4E The system and method are described in detail.

[0093] for Fig. 8AIn an exemplary aspect, method 800 generally includes placing a first solid adhesive film on an alignment tool at (802); peeling off the backing material from the first solid adhesive film on one side of a panel to be bonded to a perforated panel at (804); placing the first solid adhesive film and the alignment tool on the perforated panel at (806) to align the perforations; removing the alignment tool at (808); applying a second solid adhesive film to the other side of the panel at (810); perforating the second solid adhesive film using hot air at (812); removing a second release film / paper from the first solid adhesive film at (814); bonding the acoustic screen to the first solid adhesive film at (816); and bonding the acoustic core to the second solid adhesive film at (818).

[0094] for Figure 8B In an exemplary aspect, method 850 generally includes placing a first solid adhesive film on an alignment tool at (852); peeling off the backing material from the first solid adhesive film on one side of the panel to be bonded to the perforated panel at (854); placing the first solid adhesive film and the alignment tool on the perforated panel at (856) to align the perforations; removing the alignment tool at (858); applying a second solid adhesive film to the other side of the panel at (860); perforating the second solid adhesive film using hot air at (862); bonding the acoustic core to the second solid adhesive film at (864); removing the second release film / paper from the first solid adhesive film at (866); and bonding the acoustic screen to the first solid adhesive film at (868).

[0095] for Fig. 9A In an exemplary aspect, method 900 generally includes applying an alignment tool to a perforated panel at (902), wherein pins or protrusions of the alignment tool extend through perforations of the panel; peeling off a backing material from a first solid adhesive film on a side to be bonded to the panel at (904); placing the perforated panel and the alignment tool on the first solid adhesive film at (906), aligning the perforations; removing the alignment tool at (908); applying a second solid adhesive film to the other side of the panel at (910); perforating the second solid adhesive film using hot air at (912); removing a second release film / paper from the first solid adhesive film at (914); bonding an acoustic screen to the first solid adhesive film at (916); and bonding an acoustic core to the second solid adhesive film at (918).

[0096] for Fig. 9BIn an exemplary aspect, method 950 generally includes applying an alignment tool to a perforated panel at (952), wherein pins or protrusions of the alignment tool extend through the perforations of the panel; peeling off the backing material from a first solid adhesive film on one side to be bonded to the panel at (954); placing the perforated panel and the alignment tool on the first solid adhesive film at (956), aligning the perforations; removing the alignment tool at (958); applying a second solid adhesive film to the other side of the panel at (960); perforating the second solid adhesive film using hot air at (962); bonding the acoustic core to the second solid adhesive film at (964); removing the second release film / paper from the first solid adhesive film at (966); and bonding the acoustic screen to the first solid adhesive film at (968).

[0097] Reference now Fig.10 , an exemplary embodiment of the acoustic liner system 500 of the present disclosure will now be described. In a first configuration, the present disclosure uses a solid adhesive film to bond an acoustic screen to an acoustic liner 100 ( Figure 1A and 2 ) panel method can produce Fig.10 For example, system 500 includes a top-down configuration including perforated screen 502 , solid adhesive membrane 504 , face plate 506 , and acoustic core 508 .

[0098] Reference now Fig.11 , another exemplary embodiment of the acoustic liner system 550 of the present disclosure will now be described. In a second configuration, the present disclosure uses a solid adhesive film to bond the acoustic screen to the acoustic liner 100 ( Figure 1A and 2 ) panel method can produce Fig.11 For example, system 500 includes a top-down configuration including panel 556 , solid adhesive membrane 554 , perforated screen 552 , and acoustic core 558 .

[0099] Reference now Fig.12 , a method 1200 for bonding a panel of an acoustic liner using a solid adhesive film having a first adhesive surface opposite a second adhesive surface is provided. In certain exemplary aspects, the method 1200 can be used with one or more of the exemplary systems or methods described above.

[0100] The method 1200 includes, at (1202), bonding a panel to a first bonding surface of a solid bonding film, as described in detail above.

[0101] The method 1200 further includes bonding the acoustic liner to the second bonding surface of the solid bonding film at (1204), as described in detail above.

[0102] Further aspects of the disclosure are provided by the subject matter of the following clauses:

[0103] An acoustic liner includes: a solid adhesive film having a first adhesive surface opposite to a second adhesive surface; an acoustic screen bonded to the first adhesive surface of the solid adhesive film; and a panel bonded to the second adhesive surface of the solid adhesive film.

[0104] An acoustic liner according to any preceding clause, wherein the solid adhesive film comprises an elastic strip.

[0105] An acoustic liner according to any preceding clause, wherein the first adhesive side and the second adhesive side of the solid adhesive film each comprise a pressure sensitive adhesive.

[0106] An acoustic liner according to any preceding clause, further comprising an acoustic core bonded to said acoustic screen or said panel.

[0107] A method for bonding a panel and an acoustic shield of an acoustic liner together using a solid adhesive film, the solid adhesive film having a first adhesive surface opposite to a second adhesive surface, the method comprising: bonding the panel to the first adhesive surface of the solid adhesive film; and bonding the acoustic shield to the second adhesive surface of the solid adhesive film.

[0108] A method according to any preceding clause, wherein the solid adhesive film comprises an elastic band.

[0109] A method according to any preceding clause, wherein both the first adhesive side and the second adhesive side of the solid adhesive film comprise a pressure sensitive adhesive.

[0110] A method according to any preceding clause, further comprising perforating the solid adhesive film and / or the panel.

[0111] A method according to any preceding clause, wherein perforating the solid adhesive film and / or the panel occurs after the panel has been bonded to the solid adhesive film.

[0112] A method according to any preceding clause, wherein a plurality of perforations are made simultaneously through said panel and said solid adhesive film using a machining tool.

[0113] A method according to any preceding clause, wherein the machining tool comprises a laser cut or punch die.

[0114] A method according to any preceding clause, wherein a plurality of perforations are made first through the panel and then through the solid adhesive film.

[0115] A method according to any preceding clause, wherein a plurality of perforations are made first through the solid adhesive film and then through the panel.

[0116] The method according to any preceding clause, further comprising: aligning the solid adhesive film and the panel using an alignment tool before bonding the panel to the first adhesive face of the solid adhesive film.

[0117] A method according to any preceding clause, wherein the alignment means comprises a protrusion capable of being positioned simultaneously within the one or more perforations of the panel and within the one or more perforations of the solid adhesive film.

[0118] A method according to any preceding clause, wherein aligning the solid adhesive film and the panel using an alignment tool comprises placing the solid adhesive film in the alignment tool and then pressing the alignment tool with the solid adhesive film onto the panel to bond the panel to the first adhesive face of the solid adhesive film.

[0119] A method according to any preceding clause, wherein aligning the solid adhesive film and the panel using an alignment tool comprises placing the panel in the alignment tool and then pressing the alignment tool with the panel onto the solid adhesive film to bond the panel to the first bonding surface of the solid adhesive film.

[0120] The method of any preceding clause, further comprising aligning the solid adhesive film and the acoustic shield using an alignment tool prior to bonding the acoustic shield to the second adhesive face of the solid adhesive film.

[0121] A method according to any preceding clause, further comprising bonding an acoustic core to said acoustic screen or said panel.

[0122] A method according to any preceding clause, further comprising bonding a back sheet to the acoustic core.

[0123] This written description uses examples to disclose the present disclosure, including the best mode, and also to enable any person skilled in the art to practice the present disclosure, including making and using any device or system and performing any combined methods. The patentable scope of the present disclosure is defined by the claims, and may include other examples that occur to one skilled in the art. If such other examples include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims, they are intended to be within the scope of the claims.

[0124] Although the present disclosure has been described as having an exemplary design, the present disclosure may be further modified within the scope of the present disclosure. Therefore, the present application is intended to cover any variation, use or adaptation of the present disclosure using its general principles. Further, the present application is intended to cover such deviations from the present disclosure as are known or customary in the art to which the present disclosure belongs and fall within the limits of the appended claims.

Claims

1. A sound lining, characterized in that: include: a solid adhesive film having a first adhesive surface and a second adhesive surface opposite the first adhesive surface, the solid adhesive film comprising a plurality of perforations; an acoustic shield bonded to the solid adhesive film along the first adhesive face, wherein the acoustic shield is a sheet, a mesh, or a combination thereof; a panel bonded to the solid adhesive film along the second adhesive surface; and An acoustic core is bonded to the face sheet, wherein the solid adhesive film and the face sheet are sandwiched between the acoustic shield and the acoustic core.

2. The acoustic lining according to claim 1, characterized in that: in, The solid adhesive film includes an elastic band.

3. The acoustic lining according to claim 2, characterized in that: in, The first adhesive side and the second adhesive side of the solid adhesive film each include a pressure sensitive adhesive.

4. The acoustic liner according to claim 1, characterized in that: Further including: A second solid adhesive film, wherein the acoustic core is bonded to the panel by the second solid adhesive film.

5. A method for forming an acoustic liner, characterized in that: The method comprises: bonding the panel to the first bonding surface of the solid bonding film; bonding an acoustic shield to the second adhesive face of the solid adhesive film, wherein the acoustic shield is a sheet, a mesh, or a combination thereof; and bonding an acoustic core to the panel; Wherein the panel comprises panel perforations, the solid adhesive film comprises film perforations, and the acoustic screen comprises screen perforations, and wherein the panel perforations, the screen perforations, and the film perforations are aligned.

6. The method according to claim 5, characterized in that in, The solid adhesive film includes an elastic band.

7. The method according to claim 6, characterized in that in, The first adhesive side and the second adhesive side of the solid adhesive film each include a pressure sensitive adhesive.

8. The method according to claim 5, characterized in that Further including: The solid adhesive film and / or the panel are perforated.

9. The method according to claim 8, characterized in that in, Perforating the solid adhesive film and / or the panel occurs after the panel has been bonded to the solid adhesive film.

10. The method according to claim 9, characterized in that in, A plurality of perforations are simultaneously made through the panel and the solid adhesive film using a machining tool.

11. The method according to claim 10, characterized in that in, The machining tools include laser cutting or punching dies.

12. The method according to claim 9, characterized in that in, A plurality of perforations are made first through the panel and then through the solid adhesive film.

13. The method according to claim 9, characterized in that in, A plurality of perforations are made first through the solid adhesive film and then through the panel.

14. The method according to claim 5, characterized in that Further including: Before bonding the panel to the first bonding surface of the solid bonding film, the solid bonding film and the panel are aligned using an alignment tool.

15. The method according to claim 14, characterized in that in, The alignment tool comprises a protrusion capable of being simultaneously positioned within the one or more perforations of the panel and within the one or more perforations of the solid adhesive film.

16. The method according to claim 15, characterized in that in, Aligning the solid adhesive film and the panel using an alignment tool includes placing the solid adhesive film in the alignment tool and then pressing the alignment tool with the solid adhesive film onto the panel to adhere the panel to the first adhesive face of the solid adhesive film.

17. The method according to claim 15, characterized in that in, Aligning the solid adhesive film and the panel using an alignment tool includes placing the panel in the alignment tool and then pressing the alignment tool with the panel onto the solid adhesive film to bond the panel to the first adhesive face of the solid adhesive film.

18. The method according to claim 14, characterized in that Further including: Prior to bonding the acoustic shield to the second bonding face of the solid adhesive film, the solid adhesive film and the acoustic shield are aligned using an alignment tool.

19. The method according to claim 5, characterized in that Further including: The acoustic core is bonded to the face plate via a second solid adhesive film.

20. The method according to claim 19, characterized in that Further including: A back panel is bonded to the acoustic core.

Images