Acoustic Bond Panel Co-Curing and Insert Integration
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Solution Overview
Problem
The existing process for manufacturing acoustic bond panels in aircraft nacelle systems is costly and restrictive due to the need for multiple autoclave runs and the requirement that all materials withstand high temperatures and pressures, limiting the types of cores that can be used.
Innovation Solution
A method that reduces the number of autoclave runs by co-curing the top skin, core, and back skin in a single operation, allowing for the use of materials that cannot withstand high temperatures and pressures, and includes the integration of acoustic insert assemblies using low-temperature adhesives for assembly and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multi-step autoclave process is used, then manufacturing precision and material compatibility are improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent combines multiple separate autoclave operations into a single integrated autoclave run. The top skin and back skin are cured simultaneously in one autoclave cycle, eliminating the need for separate curing operations. This merging of processes reduces the total number of autoclave runs from multiple to one, thereby reducing process complexity while maintaining manufacturing precision through controlled single-cycle curing parameters.
Solution Approach 2:
The patent applies preliminary action by pre-positioning the top skin on the bond tool, adding core blankets and back skin layers in a predetermined sequence before the single autoclave run. This preliminary assembly preparation ensures that all components are correctly positioned and ready for the unified curing process, maintaining manufacturing precision while enabling the simplified single-cycle approach.
2Strength
If all materials must withstand autoclave temperature and pressure, then structural integrity is improved, but material selection flexibility deteriorates
Solution Approach 1:
The patent segments the panel construction into two distinct groups: structural components (top skin, back skin, core blankets) that undergo autoclave curing to ensure structural integrity, and acoustic treatment elements that can be added separately using materials not suitable for high-temperature autoclave processes. This segmentation allows each component group to be treated according to its specific material requirements, maintaining overall strength while expanding material selection flexibility for acoustic treatments.
Solution Approach 2:
The patent uses an intermediary approach by introducing acoustic treatment elements as separate insertable assemblies that are bonded to the cured panel structure using adhesives or other joining methods. These acoustic elements serve as intermediary components that do not need to withstand autoclave conditions, as they are added after the structural portion is cured. This allows the use of diverse materials for acoustic treatments without compromising the structural integrity of the main panel.
3Manufacturing precision
If multiple process steps are used, then panel quality is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent merges multiple sequential process steps into a more integrated workflow. By combining the curing of top skin and back skin into a single autoclave operation and allowing acoustic treatments to be added separately rather than requiring separate autoclave cycles, the overall manufacturing process is streamlined. This reduces the total number of process steps and autoclave runs, thereby improving productivity and reducing manufacturing time while maintaining panel quality through controlled single-cycle curing.
Solution Approach 2:
The patent applies preliminary action by preparing the structural panel assembly (top skin, core, back skin) in advance through a single autoclave cure cycle, creating a ready-to-receive base structure. This preliminary completion of the structural portion allows acoustic treatment elements to be added subsequently without requiring additional autoclave time, thus improving manufacturing efficiency by enabling parallel or sequential addition of non-structural elements after the main curing operation is complete.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing costs and expands material flexibility, enabling the use of materials not suitable for traditional autoclave processes while maintaining effective noise attenuation through the integration of acoustic insert assemblies.
Implementation Method 1
applying a first adhesive to a cavity of a bond panel; inserting an acoustic insert assembly in the cavity, the acoustic insert assembly being secured in the cavity by the first adhesive; and securing edges of the acoustic insert assembly to the raised body portion of the bond panel with a second adhesive
Implementation Method 2
placing the bagged assembly in an autoclave; subjecting the bagged assembly to a pressure and a temperature for a determined amount of time. In this regard, the back skin, the core, and the top skin may be co-cured in a single autoclave pressurization and heating operation
Implementation Method 3
subjecting the bagged assembly to a pressure and a temperature for a determined amount of time
Data Source
AI summary
Method of manufacturing bond panels and bond panel assemblies are provided. In various embodiments, the method may comprise laying up a top skin on a tool comprising a mandrel. The method may further comprise laying out core on the top skin. The method may further comprise laying up back skin to create an assembly. The assembly may comprise the top skin, the core, and the back skin. The method may further comprise placing the assembly in a bag to provide a bagged assembly. The method may also comprise placing the bagged assembly in an autoclave. The method may further comprise subjecting the bagged assembly to a pressure and a temperature for a determined amount of time. In this regard, the back skin, the core, and the top skin may be co-cured in a single autoclave pressurization and heating operation.