Cascade Array Vanes With Overlapping Longitudinal Portions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional thrust reverser cascade arrays for aircraft propulsion systems face challenges in manufacturing complexity and structural integrity due to the need for precise fitting within non-cylindrical spaces and the use of materials that are not always optimal for strength and weight.
Innovation Solution
The development of a cascade array vane system using thermoset components, where strongbacks and vanes are formed separately and coupled using thermoplastic coatings or adhesives, allowing for easier assembly and improved structural support through overlapping longitudinal portions and mating geometries like shiplap joints, facilitating a strong and lightweight design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional cascade arrays use traditional materials and manufacturing methods, then structural integrity may be maintained, but manufacturing complexity and cost increase
Solution Approach 1:
The cascade array is divided into multiple separate vanes that can be manufactured independently and then assembled together. Each vane is formed as a separate component using compression molding, allowing for simplified manufacturing processes while maintaining structural integrity through the array configuration
Solution Approach 2:
The patent utilizes composite materials for the vanes, combining different material properties to achieve both structural integrity and manufacturing efficiency. The composite construction allows for lightweight design while maintaining the necessary strength and durability for thrust reverser operation
2Productivity
If cascade arrays are designed to fit non-cylindrical spaces, then aerodynamic performance improves, but manufacturing precision requirements increase
Solution Approach 1:
By segmenting the cascade array into individual vanes with standardized cross-sections, the system can be assembled to fit complex non-cylindrical spaces without requiring each component to be precision-manufactured to complex geometries. The modular nature allows for easier adaptation to varying spatial requirements
Solution Approach 2:
The vane design incorporates specific geometric features at particular locations to optimize aerodynamic performance in different regions of the cascade array. Each vane can be tailored with local geometric variations while maintaining a standardized overall structure that simplifies manufacturing
3Strength
If cascade arrays use heavier materials for strength, then structural integrity improves, but weight increases
Solution Approach 1:
Composite materials provide high strength-to-weight ratio, allowing the cascade array to maintain structural integrity while significantly reducing weight compared to traditional metallic constructions. The composite structure can be engineered to provide strength where needed while minimizing material usage
Solution Approach 2:
Dividing the cascade array into separate vane components allows for optimized material distribution, placing material only where structural support is needed rather than using solid construction throughout. This segmentation enables weight reduction while maintaining overall structural integrity
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 simplifies the manufacturing process, reduces costs, and enhances the structural integrity and aerodynamic performance of the thrust reverser system by using composite materials and efficient coupling methods, enabling better fitment within confined spaces and improved reverse thrust generation.
Implementation Method 1
A thermoplastic coating is applied to a strongback and heated to a melting point
Implementation Method 2
The heated thermoplastic coating is pressed against a vane to bond the vane to the strongback
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A cascade array vane is provided that includes a vane (404; 406), a first longitudinal portion (410; 416), a second longitudinal portion (412; 418), and at least one coupling feature (430). The vane (404; 406) includes an airfoil portion (408; 414) extending between a first end and a second end. The first longitudinal portion (410; 416) is disposed at the first end of the vane (404; 406) extending outwardly from the vane (404; 406). The second longitudinal portion (412; 418) is disposed at the second end of the vane (404; 406) extending outwardly from the vane (404; 406). The at least one coupling feature (430) is incorporated with at least one of the first longitudinal portion (410; 416) or the second longitudinal portion (412; 418).