Capsular Skin Acoustic Panel for Aircraft Noise Attenuation
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Solution Overview
Problem
The industrial methods for manufacturing acoustic panels with integrated capsules for aircraft nacelles are complex and expensive, making them difficult to implement on an industrial scale.
Innovation Solution
A novel acoustic panel design featuring a capsular skin formed from a continuous layer of polymerized material, integrated into a cellular structure with channels at the apex of each capsule for acoustic wave passage, and a simplified manufacturing method that eliminates the need for precise positioning and adhesive bonding of independent components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional methods are used to manufacture acoustic panels with integrated capsules, then the acoustic performance is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the capsule structure and skin into a single integrated component formed by molding polymerizable material around a cellular structure. This eliminates the need for separate capsule insertion and skin attachment steps, reducing manufacturing complexity while maintaining acoustic performance through the integrated design.
Solution Approach 2:
The invention performs preliminary action by pre-forming the capsular skin with embedded capsules in a mold before assembly. The polymerizable material is shaped around the cellular structure in advance, creating pre-assembled units that simplify final panel construction and reduce on-site manufacturing complexity.
2Reliability
If traditional methods are used to manufacture acoustic panels with integrated capsules, then the acoustic performance is improved, but the production time and cost increase
Solution Approach 1:
The patent combines multiple manufacturing operations into a single molding process where capsules and skin are formed simultaneously. This integration eliminates sequential steps (capsule insertion, positioning, adhesive bonding), dramatically reducing production time and increasing manufacturing efficiency while preserving acoustic performance.
Solution Approach 2:
The invention changes the physical state of the polymerizable material from liquid to solid through polymerization. This phase transition enables the material to conform to the cellular structure during molding, then固化 into a stable integrated component, streamlining the manufacturing process and improving production efficiency.
3Ease of manufacture
If a continuous layer of polymerizable material is used to form the capsular skin, then the ease of manufacture is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes the parameter change of polymerizable material during phase transition. The liquid state allows easy conforming to the cellular structure with minimal precision requirements, while the solidified state provides the necessary structural integrity and dimensional accuracy, effectively decoupling ease of manufacture from precision requirements.
Solution Approach 2:
The polymerizable material performs self-service by automatically conforming to the cellular structure's geometry during molding. The material self-adjusts to capture the precise shape and positioning of capsules and skin features without requiring high-precision tooling or manual intervention, reducing both manufacturing difficulty and precision demands.
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 solution allows for easier, quicker, and less expensive industrial-scale production of acoustic panels that effectively attenuate noise, particularly low frequencies, while offering weight savings and flexibility in frequency damping ranges.
Implementation Method 1
a continuous layer of polymerized material, obtained by molding a polymerizable material in a mold
Implementation Method 2
at least one channel being provided in the vicinity of an apex of each capsule for the passage of acoustic waves
Implementation Method 3
the core being involved in both the mechanical integrity of the panel and acoustic damping, the main function of the core being to trap and damp the sound waves
Data Source
AI summary
An acoustic panel comprising a cellular structure, such as a honeycomb structure, having cells that open at least onto a first frontal face of the structure. The panel comprises a capsular skin which is fastened to the first frontal face of the cellular structure next to a plurality of cells. The capsular skin including a continuous layer of material, in one piece, forming capsules that extend into the cellular structure. At least one channel is provided at the apex of each capsule for the passage of acoustic waves. Such a panel effectively attenuates the noise of aircraft engines, in particular, the low frequencies. It is extremely easy to manufacture industrially, the capsular skin being able to be obtained by molding with polymerization in situ, the polymerizable material then adhering to the cellular structure while it polymerizes.