Acoustic Honeycomb Plug Bonding via Thin Film Seam
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Solution Overview
Problem
Existing methods for repairing acoustic honeycomb panels in jet engines face challenges in maintaining the acoustic properties of the panel when inserting a plug, as traditional adhesive seams alter the acoustic impedance and are heavy, stiff, and difficult to shape.
Innovation Solution
A honeycomb-supported adhesive seam is used to bond an acoustic honeycomb plug into a damaged panel, creating a secure bond without significantly altering the acoustic properties by matching the plug's shape and size to the hole, and using a flexible ribbon-shaped honeycomb support to minimize interference with the panel's acoustic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional adhesive seams are used to bond honeycomb sections, then bonding strength is improved, but acoustic properties are altered and weight increases
Solution Approach 1:
The patent uses a thin film adhesive applied only at the seam line between honeycomb sections, rather than filling the entire seam area. This thin film approach provides sufficient bonding strength while minimizing interference with acoustic wave propagation through the honeycomb structure, thus preserving acoustic properties.
Solution Approach 2:
The adhesive is applied locally only at the seam line where bonding is required, rather than throughout the entire honeycomb structure. This localized application ensures strong bonding at the joint while leaving the acoustic performance of the bulk honeycomb material unaffected.
2Strength
If foam-type adhesive is used to fill seam line, then bonding strength is improved, but weight increases
Solution Approach 1:
The patent employs a thin film adhesive instead of bulk foam adhesive, applying the adhesive only as a thin layer at the seam line. This reduces the amount of adhesive material significantly, thereby reducing weight while maintaining adequate bonding strength for the honeycomb joint.
Solution Approach 2:
The patent extracts only the essential bonding function from the adhesive, removing the excess foam material that would add weight. By taking out only the necessary adhesive layer at the seam line, the solution achieves bonding strength without the penalty of excessive weight from foam filling.
3Strength
If wide adhesive seams are used, then bonding strength is improved, but flexibility and shapeability decrease
Solution Approach 1:
The thin film adhesive creates a narrow, flexible bond line that does not restrict the flexibility of the honeycomb sections. This allows the bonded structure to be shaped and bent as needed, maintaining adaptability for complex curved structures like engine nacelles while providing sufficient bonding strength.
Solution Approach 2:
The adhesive application is segmented to only the narrow seam line rather than a wide continuous area. This segmentation creates discrete bonding points that preserve the flexibility and shapeability of the honeycomb sections while still achieving the necessary bond strength at the joint.
4Strength
If adhesive fills partial cells at seam line, then bonding surface area is improved, but acoustic properties are altered
Solution Approach 1:
The thin film adhesive is applied only at the seam line without filling the partial cells or open spaces. This approach provides adequate bonding surface area at the joint while leaving the cell structures open, thereby maintaining the acoustic impedance and resonator function of the honeycomb cells.
Solution Approach 2:
The adhesive application is localized precisely to the seam line area where bonding is needed, avoiding intrusion into the partial cells. This local quality approach ensures sufficient bonding surface area at the joint while preserving the acoustic properties of the cell structures that would be affected if cells were filled.
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 method provides a secure, flexible bond that maintains the original acoustic properties of the panel, reducing weight and allowing for easier shaping of the bonded structure, while minimizing interference with the panel's acoustic performance.
Implementation Method 1
The seam channel is filled with an adhesive to provide bonding of the acoustic honeycomb plug to the panel
Data Source
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AI summary
An acoustic honeycomb panel is plugged with an acoustic honeycomb plug. The acoustic honeycomb plug is adhesively bonded in the gpanel using a honeycomb seam. The honeycomb seam is composed of a honeycomb support that is located within the seam channel and an adhesive. Using honeycomb seams to adhesively bond acoustic honeycomb plugs into acoustic honeycomb panels is useful in repairing damaged areas of acoustic honeycomb panels that are located in the acoustic treatments for jet engines.