Cellular Core Panel Rework Without Blocking Acoustic Cells
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Solution Overview
Problem
Existing methods for reworking acoustic panels in aircraft engine assemblies, such as those with honeycomb cores, often result in blocked cells and reduced acoustic performance, which can lead to costly replacements due to regulatory constraints and inefficiencies in restoring structural and acoustic integrity.
Innovation Solution
A method involving a guide and cutting instrument apparatus that allows for precise removal and replacement of cellular core sections within acoustic panels, maintaining intact septums and cell walls, enabling in-situ rework of large structures with minimal disruption, using a guide with legs that fit into cellular cores and a cutting instrument to sever cell walls at junctures, followed by insertion of rework section plugs and adhesive application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If known reworking methods involving splicing and foaming adhesives are used, then structural repair is achieved, but acoustic performance deteriorates due to blocked honeycomb cells
Solution Approach 1:
The repair method segments the repair process into distinct phases: removing damaged cells, inserting new cellular material, and sealing with adhesive only at cell junctions. This segmentation prevents adhesive from blocking entire cells while still achieving structural repair, thus maintaining acoustic performance.
Solution Approach 2:
The adhesive is applied locally only at cell wall junctions rather than throughout the entire honeycomb structure. This localized application ensures that cell interiors remain open and unblocked, preserving acoustic performance while providing sufficient bonding strength at critical connection points.
2Reliability
If acoustic panels are replaced entirely to maintain acoustic performance, then acoustic performance is restored, but cost and time increase significantly
Solution Approach 1:
The method performs preliminary selective removal of only the damaged cellular sections rather than the entire panel. This allows the majority of the original acoustic panel to be retained and reused, significantly reducing replacement time and cost while maintaining acoustic performance through targeted repair.
Solution Approach 2:
Instead of discarding the entire acoustic panel, the method recovers and reuses the undamaged portions of the honeycomb structure. Only the specific damaged cells are removed and replaced, maximizing material utilization and minimizing waste while maintaining overall acoustic performance.
3Strength
If adhesive is applied extensively to secure reworked sections, then structural integrity is improved, but cell blockage increases reducing acoustic performance
Solution Approach 1:
Adhesive application is restricted to local areas at cell wall junctions where structural bonding is most critical. This localized approach provides sufficient structural integrity while leaving cell interiors open, thereby preventing adhesive-induced blockage and preserving acoustic performance.
Solution Approach 2:
The method uses partial adhesive action only where structurally necessary at junctions, rather than excessive adhesive application throughout. This partial application achieves adequate structural bonding without over-saturation that would block cells and degrade acoustic performance.
Data Source
AI summary
Methods for reworking structures and reworked cellular core panels, reworked structures comprising the reworked cellular core panels, and guides and cutting apparatuses for reworking cellular acoustic panels and reworking cellular acoustic and non-acoustic panels are disclosed.