Acoustic Bond Panel Insertion Method for Aircraft Nacelles
Find Innovative SolutionsGenerate Solutions
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 involving the application of adhesives to secure acoustic insert assemblies within cavities of bond panels, allowing for the use of materials that cannot withstand autoclave conditions, and co-curing the panel components in a single autoclave operation, reducing the number of steps and enabling the integration of non-traditional materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If all materials are required to withstand autoclave temperature and pressure, then the structural integrity of the panel is ensured, but the selection of core materials is limited
Solution Approach 1:
The panel is divided into separate components: a structural shell that undergoes autoclave curing and acoustic core materials that are inserted afterward. This segmentation allows each component to be optimized independently - the shell provides structural integrity through high-temperature curing while the core can use materials unsuitable for autoclave conditions
Solution Approach 2:
The structural shell is prepared in advance by forming and curing it in the autoclave before the acoustic core materials are inserted. This preliminary action ensures the shell achieves full structural properties before receiving the sensitive core materials, allowing those materials to be selected based on acoustic performance rather than thermal resistance
2Manufacturing precision
If multiple autoclave runs are used to form different panel components separately, then each component can be optimized, but the manufacturing cost and time increase
Solution Approach 1:
The invention merges the assembly of multiple panel components into a single autoclave run. The shell and core materials are assembled together in the autoclave simultaneously, eliminating the need for separate curing cycles for each component while still allowing each to be optimized for its specific function
3Adaptability or versatility
If acoustic insert assemblies are inserted after panel formation, then materials unsuitable for autoclave can be used, but additional assembly steps are required
Solution Approach 1:
The shell is prepared with pre-formed cavities and attachment features during the initial autoclave curing process. These preliminary structures are built in advance to receive and secure the acoustic insert assemblies, eliminating the need for complex post-assembly operations while still allowing material flexibility
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 by allowing the use of materials unsuitable for high-temperature 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
Implementation Method 2
securing edges of the acoustic insert assembly to the raised body portion of the bond panel with a second adhesive to create a seamless interface
Implementation Method 3
placing the bagged assembly in an autoclave; subjecting the bagged assembly to a pressure and a temperature for a determined amount of time; the back skin, the core, and the top skin may be co-cured in a single autoclave pressurization and heating operation
Data Source
AI summary
A method may comprise applying a first adhesive to a cavity of a bond panel, the cavity defined by a raised body portion of the 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 to create a seamless interface between the edges and the raised body portion.