Mechanically Interlocking Honeycomb Core Joints for Acoustic Liners
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Solution Overview
Problem
Existing methods for joining honeycomb composite sandwich panel sections obstruct sound waves by filling cells and blocking openings with adhesives, reducing the noise suppression capability of acoustic liners.
Innovation Solution
Mechanically interlocking the edge cell walls of adjacent honeycomb core sections without using adhesives, forming joints that allow for maximum sound absorption by maintaining open cells and face sheet openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If foaming adhesive is used to join honeycomb panel sections, then the joint strength and structural integrity are improved, but the sound suppression capability deteriorates due to obstruction of cells and face sheet openings
Solution Approach 1:
The invention extracts and removes the obstructing adhesive material from the cells and face sheet openings. By using a two-step process where adhesive is initially applied and then excess adhesive is removed by vacuum suction, the harmful obstruction is eliminated while retaining the beneficial bonding, thereby restoring sound suppression capability while maintaining joint strength
Solution Approach 2:
The invention discards the excess adhesive that obstructs sound waves by applying vacuum suction to remove it from cells and face sheet openings. This selective removal process discards only the harmful portion of the adhesive while preserving the bonding function, thus recovering the sound suppression capability without sacrificing joint strength
2Strength
If foaming adhesive fills cells along adjoined edges, then the bonding between sections is improved, but the acoustically treated area is reduced due to blocked cells and openings
Solution Approach 1:
The invention extracts adhesive from cells and face sheet openings using vacuum suction. This removal process recovers the acoustically treated area by eliminating adhesive obstructions while preserving the bonding between sections, thus resolving the contradiction between bonding strength and acoustically treated area
Solution Approach 2:
The invention discards excess adhesive that blocks cells and openings, thereby recovering the full acoustically treated area. The vacuum suction process selectively removes adhesive from acoustic pathways while maintaining the bonding function, achieving both strong bonding and maximum acoustic treatment area
Data Source
AI summary
Adjoining edges of adjacent honeycomb core panel sections are mechanically interlocked. In one embodiment, the method includes forming a first edge along a first cellular core panel section. The first edge includes a first plurality of edge cell walls along the first edge. The method further includes forming a second edge along a second cellular core panel section, wherein the second edge includes a second plurality of edge cell walls along the second edge. The first edge is positioned proximate to the second edge. At least a portion of at least one of the first plurality of edge cell walls is mechanically interlocked with at least a portion of at least one of the second plurality of edge cell walls to form a joint therebetween. A composite structure may be at least partially produced by such a method.