Hybrid Thrust Reverser Inner Wall Composite Structure
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Solution Overview
Problem
Aircraft nacelle thrust reversers face challenges in withstanding high engine temperatures while being economical, lightweight, and easy to manufacture, as existing titanium solutions are expensive and heavy, and composite materials require external heat shielding that adds weight and complexity.
Innovation Solution
A method involving a face sheet, a core with cell walls, and a back sheet sandwiched together with an electro-depositable material like nickel, which enhances bonding and thermal conductivity, and optionally a thermally conductive coating for improved heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If titanium thrust reverser inner walls are used to withstand high engine temperatures, then temperature resistance is improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent employs a composite sandwich structure consisting of aluminum alloy face sheets, honeycomb core, and titanium reinforcement ribs. This composite construction achieves the required temperature resistance and structural strength while significantly reducing weight compared to solid titanium walls. The aluminum face sheets provide thermal barrier properties, the honeycomb core offers lightweight structural support, and titanium ribs provide localized heat resistance where needed.
Solution Approach 2:
The thrust reverser inner wall is segmented into distinct functional zones: aluminum alloy face sheets for thermal insulation, honeycomb core for lightweight structure, and titanium reinforcement ribs for localized strength and heat resistance. This segmentation allows each material to perform its optimal function while minimizing overall weight.
2Temperature
If titanium thrust reverser inner walls are used to withstand high engine temperatures, then temperature resistance is improved, but manufacturing cost increases
Solution Approach 1:
The composite sandwich structure uses cost-effective aluminum alloy face sheets and honeycomb core materials, reserving expensive titanium for only the necessary reinforcement ribs. This material optimization significantly reduces manufacturing cost while maintaining the required temperature resistance and structural integrity.
Solution Approach 2:
Titanium reinforcement ribs are strategically placed only in areas requiring high temperature resistance and structural strength, rather than using titanium throughout the entire inner wall. This localized application of expensive material optimizes both performance and cost-effectiveness.
3Weight of moving object
If composite materials are used for thrust reverser inner walls, then weight is reduced, but external heat shielding is required adding weight and complexity
Solution Approach 1:
The aluminum alloy face sheets with honeycomb core and titanium rib reinforcement create an integrated composite structure that provides both structural support and thermal management. The aluminum face sheets act as thermal barriers, eliminating the need for separate external heat shielding components and reducing overall system complexity.
Solution Approach 2:
The structural and thermal management functions are merged into a single integrated composite sandwich structure. The aluminum face sheets simultaneously provide structural integrity and thermal insulation, while the titanium ribs provide both structural reinforcement and localized heat resistance, eliminating the need for separate heat shielding systems.
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 provides a lightweight, cost-effective, and high-performance thrust reverser inner wall that effectively manages heat, reducing the need for external shielding and maintaining structural integrity.
Implementation Method 1
electrodepositing an electro-depositable material, such as nickel, substantially continuously over the outer core surface, the cell walls, and the outer face sheet surface, thereby bonding the face sheet and core together
Implementation Method 2
a thermally conductive coating may be deposited/bonded to the inner face sheet surface
Data Source
AI summary
An aircraft thrust reverser inner wall and method of manufacturing the same. The aircraft thrust reverser inner wall may include a face sheet, a perforated back sheet, and a core sandwiched between the face sheet and the perforated back sheet. The face sheet may have an inner face sheet surface and an outer face sheet surface, and the core may have an inner core surface, an outer core surface, and a plurality of cell walls extending therebetween. An electro-depositable material may be applied, via electrodeposition, in a substantially continuous layer over the outer core surface, the cell walls, and the outer face sheet surface, thus bonding the face sheet and core together. The perforated back sheet may be attached to the core at the outer core surface, and a conductive coating may be applied to the inner face sheet surface.