Cellular Core Panel Rework Without Honeycomb Cell Blockage

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Solution Overview

Problem

Existing methods for reworking acoustic panels in aircraft engine assemblies result in blocked honeycomb cells, leading to reduced acoustic performance and high costs due to part replacement, while regulatory requirements for acoustic restoration vary across aircraft types.

Innovation Solution

A cutting apparatus and method using a guide with a base and legs that fit into cellular core sections, allowing precise removal and replacement of cellular core sections with matching plugs, maintaining intact septums and structural integrity, and adhering the replacement with adhesive layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If foaming adhesives are used to secure reworked sections, then structural strength is restored, but honeycomb cells are blocked resulting in reduced acoustic performance

Engineering Contradiction:

Improvestructural strengthVSAvoidacoustic performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent removes the harmful foaming adhesive from the rework process entirely. Instead, it uses a plug made of cellular core material that mechanically fits into the damaged area and is secured with non-foaming adhesive, extracting the source of cell blockage while maintaining structural integrity

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the adhesive parameter from foaming to non-foaming type. This parameter change prevents cell blockage while still providing adequate bonding strength for the reworked section, thereby preserving acoustic performance

Inventive Principle:

Principle #35Parameter changes

2Reliability

If acoustic panels are replaced entirely, then acoustic performance is restored, but costs increase significantly

Engineering Contradiction:

Improveacoustic performanceVSAvoidcost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent divides the acoustic panel into replaceable segments. Only the damaged cellular core section is removed and replaced with a plug, while the remaining intact portions of the panel are retained. This segmented approach restores acoustic performance in the reworked area while avoiding the need to replace the entire expensive panel assembly

Inventive Principle:

Principle #1Segmentation

3Strength

If honeycomb cells are blocked during rework, then structural repair is achieved, but acoustic performance deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidacoustic loss

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent introduces a plug made of cellular core material as an intermediary between the damaged area and the surrounding structure. This plug serves as both a structural filler and an acoustic element that maintains cell integrity, preventing the harmful blockage effect while achieving structural repair

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4234219B1Structural rework of cellular core panels

Publication Date: 2025.10.01 THE BOEING CO

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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 non-acoustic panels are disclosed.