Bonded Cascade Assembly for Aircraft Thrust Reverser
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Solution Overview
Problem
Current methods for fabricating cascade thrust reversers, particularly for aircraft engines, face challenges in providing sufficient stiffness and resisting loads while being cost-effective and efficient, especially with the use of composite materials which require labor-intensive processes.
Innovation Solution
A bonded cascade assembly is developed using a structural frame with elongated stiffeners and turning vanes attached by structural adhesive, along with a closeout cap, fabricated from composite materials to enhance stiffness and load resistance, and a method involving the insertion and bonding of turning vanes between stiffeners and attaching a closeout cap to the aft ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used to fabricate cascade baskets, then weight is reduced and durability is improved, but manufacturing complexity and labor intensity increase
Solution Approach 1:
The cascade basket is divided into multiple components including a basket body, stiffeners, and mounting brackets that are manufactured separately and then assembled together. This segmentation allows each component to be optimized for its specific function while simplifying the overall manufacturing process compared to monolithic composite construction.
Solution Approach 2:
The invention employs composite materials such as carbon fiber reinforced polymers to construct the cascade basket components. These composite materials provide high strength-to-weight ratio and durability while allowing for tailored fabrication processes that reduce overall manufacturing complexity.
2Reliability
If composite materials are used to fabricate cascade baskets, then durability is improved, but manufacturing cost increases
Solution Approach 1:
By segmenting the cascade basket into separate components that can be manufactured using standardized processes, the invention reduces overall manufacturing cost while maintaining the durability benefits of composite materials. The modular approach allows for better inventory management and reduced waste.
Solution Approach 2:
The invention optimizes the parameters of composite materials such as fiber-to-matrix ratio, material composition, and structural configuration to achieve the required durability at lower cost. This involves selecting appropriate composite materials and designing structures that efficiently utilize these materials.
3Strength
If cascade baskets are designed to resist lateral loads from side turning flow, then structural integrity is improved, but device complexity increases
Solution Approach 1:
The cascade basket incorporates stiffeners and reinforcement elements at specific locations where lateral loads are most likely to occur, such as at the mounting interfaces and along the flow path. This localized reinforcement provides the necessary structural integrity without requiring complex strengthening throughout the entire structure.
Solution Approach 2:
The cascade basket is designed with separate stiffener components and mounting brackets that can be independently manufactured and assembled. This segmentation allows for optimized structural design at each component level, providing lateral load resistance through simple, modular elements rather than complex integrated structures.
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 provides a more automated and cost-effective fabrication method for composite cascade assemblies, maintaining strength while reducing manufacturing complexity, and effectively resisting both radial and longitudinal loads.
Implementation Method 1
The turning vanes may be attached to the elongated stiffeners by structural adhesive
Data Source
AI summary
A method of fabricating a bonded cascade assembly of a thrust reverser for an aircraft nacelle. The method may include inserting individual turning vanes between spaced apart elongated stiffeners at an aft end thereof and sliding the turning vanes toward a front frame piece attached to or integrally formed with forward ends of the elongated stiffeners. The elongated stiffeners may have inner and outer flanges for trapping and limiting radial movement of the turning vanes. The method may further include bonding the turning vanes to the structural frame with a structural adhesive and attaching a closeout cap to the aft ends of each of the elongated stiffeners.