Acoustic Panel Thermoforming Assembly to Reduce Deformation
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Solution Overview
Problem
Existing acoustic attenuation panels for airplane engines require numerous costly and delicate assembly steps, including bonding and welding, which can lead to deformation and poor acoustic performance due to the use of thermoplastic materials.
Innovation Solution
A method using a thermoforming tool to simultaneously assemble an acoustic panel by shaping a thermoplastic blank into an acoustic component, then integrating it with a multicellular body, reducing assembly steps and deformation risks through controlled temperature and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bonding operations are used to assemble acoustic panel components, then satisfactory attachment is achieved, but the process requires multiple long and costly oven or autoclave steps
Solution Approach 1:
The patent combines multiple assembly operations (bonding and welding) into a single integrated process. The acoustic component is bonded to the multicellular body while simultaneously welded to the closure skin within the same tooling, eliminating the need for separate bonding steps that would require multiple oven or autoclave cycles.
Solution Approach 2:
The acoustic component is pre-formed with bonding surfaces prepared in advance during the molding process. The bonding surfaces are positioned and oriented correctly before the final assembly operation, allowing the bonding and welding to occur simultaneously without requiring preliminary bonding steps.
2Strength
If welding is used to assemble the acoustic component with the multicellular body, then attachment is achieved, but the heat generated causes deformation of the hollow acoustic elements
Solution Approach 1:
The acoustic component is pre-assembled with the multicellular body using bonding in a cold state, establishing the correct geometric relationships and positions before the welding operation. This preliminary positioning prevents heat-induced deformation during welding.
Solution Approach 2:
The patent uses bonding as a protective intermediate step that cushions or protects the hollow acoustic elements from the harmful thermal effects of welding. The bonding creates a stable structure that can withstand the subsequent welding process without deforming.
3Ease of manufacture
If thermoplastic material with easy demoulding properties is used, then demoulding is facilitated, but the material becomes difficult to bond
Solution Approach 1:
The acoustic component is molded and demolded first while in its easy-to-demold thermoplastic state. The bonding surfaces are then prepared and positioned in advance before the bonding operation, allowing the material to be bonded effectively despite its demoldable properties.
Solution Approach 2:
The patent changes the temperature parameter of the thermoplastic material during the process. The material is in a softened state during molding for easy demoulding, then cooled to a state suitable for bonding, and finally heated again during the bonding operation to achieve satisfactory attachment.
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 method allows for rapid, cost-effective, and satisfactory attachment of acoustic panels with reduced deformation, enhancing acoustic performance and efficiency.
Implementation Method 1
shaping said blank into an acoustic component by a first bringing together of the male and female portions of the thermoforming tool, so as to close said thermoforming tool, the thermoforming tool having a temperature greater than or equal to the glass transition or melting temperature of the thermoplastic material of the blank
Implementation Method 2
cooling the thermoforming tool to a temperature less than the glass transition or melting temperature of the thermoplastic material of the acoustic component
Implementation Method 3
the male portion of the thermoforming tool having a temperature greater than the glass transition or melting temperature of the thermoplastic material or materials of the acoustic component at least in the contact areas between the acoustic component and the multicellular body
Data Source
AI summary
A method for manufacturing an acoustic panel includes at least one multicellular body and an acoustic component, the method including positioning a blank made of thermoplastic material between a male portion and a female portion of a tool; shaping the blank into an acoustic component in a first bringing together of the male and female portions, so as to close the tool, disposing the multicellular body between the female portion of the tool and the acoustic component; and then a second bringing together of the male and female portions of the tool, so as to press the acoustic component against the multicellular body.