Acoustic Attenuation Panel With Expandable Core Reinforcement
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Solution Overview
Problem
The existing manufacturing process for acoustic attenuation panels requires two polymerization cycles, increasing time and energy consumption, and necessitates the use of specific composite materials and joining elements to achieve a solid bond between layers.
Innovation Solution
Incorporating an expandable core between the wings of a C-shaped reinforcement to withstand compressive forces during polymerization, allowing a single polymerization cycle and reducing manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two polymerization cycles are used to manufacture the acoustic attenuation panel, then the structural integrity and bonding between layers is improved, but the manufacturing time and energy consumption increase
Solution Approach 1:
The C-shaped reinforcement is pre-formed with the desired geometry and bonding surfaces before being integrated into the panel assembly. This preliminary preparation ensures that during the single polymerization cycle, the reinforcement is immediately ready to withstand compressive forces and establish strong bonds with the acoustic layers, eliminating the need for a second polymerization cycle while maintaining structural integrity
Solution Approach 2:
The patent modifies the polymerization process parameters by consolidating two separate cycles into one optimized cycle. The single cycle uses controlled temperature and pressure parameters that simultaneously achieve complete bonding between all layers and sufficient rigidity of the C-shaped reinforcement, thereby reducing manufacturing time while preserving the required structural strength
2Reliability
If two polymerization cycles are used, then the bonding between layers is improved, but the energy consumption increases
Solution Approach 1:
The C-shaped reinforcement and acoustic layers are pre-assembled in the correct configuration with proper alignment before the polymerization process. This preliminary assembly ensures that during the single polymerization cycle, all bonding surfaces are optimally positioned to achieve maximum bonding strength in one go, eliminating the need for a second energy-consuming polymerization cycle
Solution Approach 2:
The patent optimizes the polymerization parameters including temperature profile, pressure application, and cycle duration to achieve complete bonding in a single cycle. The parameters are carefully controlled to ensure sufficient energy is provided for strong inter-layer bonding without requiring repeated polymerization cycles, thereby reducing overall energy consumption while maintaining bonding quality
3Reliability
If thermoplastic composites and joining elements are used to bond layers during the second polymerization cycle, then the bonding between layers is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the complexity of thermoplastic composites and separate joining elements from the manufacturing process. Instead, it relies on the intrinsic bonding capability of the C-shaped reinforcement and acoustic layers through a single polymerization cycle, where the reinforcement's geometry and material properties enable direct bonding without additional joining components
Solution Approach 2:
The C-shaped reinforcement serves multiple functions simultaneously: it provides structural support, enables bonding with both acoustic layers, and withstands compressive forces during polymerization. This multi-functionality eliminates the need for separate joining elements and simplifies the overall manufacturing process while maintaining strong inter-layer bonding
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
The use of an expandable core in the C-shaped reinforcement enables a single polymerization cycle, thereby reducing manufacturing time and costs while maintaining structural integrity.
Implementation Method 1
the expandable core is configured to occupy a first unexpanded state, at a first temperature, in which the expandable core occupies a first volume and a second expanded state, at a second temperature higher than the first temperature, in which the expandable core occupies a second volume larger than the first volume
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to an acoustic attenuation panel comprising at least one resistive acoustic layer (42), at least one reflective layer (46), at least one honeycomb structure (44), and at least one C-shaped reinforcement (50) interposed between the resistive acoustic and reflective layers (42, 46), as well as at least one expandable core (52), positioned between the first and second wings of the C-shaped reinforcement (50), which increases in volume during a polymerization cycle. Thanks to this expandable core (52), it is no longer necessary to perform two polymerization cycles, one of which is required to stiffen the C-shaped reinforcement (50). The invention also relates to a method for manufacturing such a panel.