Modular Turbofan Liner Assembly with Interlocking Coupling
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Solution Overview
Problem
Conventional acoustic damping liner assemblies for turbomachine casings are complex, labor-intensive, and costly to manufacture and install, requiring multiple materials and processes, and they occupy valuable space, potentially affecting aerodynamic performance.
Innovation Solution
A modular liner assembly with interlockingly engaged liner modules and coupling elements, allowing for simpler and quicker installation without the need for additional components, using an interference fit and compliant materials for secure engagement, and manufactured through processes like injection molding or 3D printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional acoustic damping liner assemblies use multiple components and materials (rails, honeycomb core, face sheet, backing sheet, polysulphide ribs), then the acoustic damping performance is achieved, but the manufacturing complexity and installation time increase significantly
Solution Approach 1:
The patent combines multiple separate components (face sheet, honeycomb core, backing sheet, and compliance layer) into a single integrated acoustic liner assembly. This merging maintains the acoustic damping functionality while eliminating the complexity of assembling multiple separate parts, directly resolving the contradiction between performance reliability and assembly complexity.
Solution Approach 2:
The patent segments the acoustic liner assembly into modular panels that can be independently manufactured and then assembled. Each panel is a self-contained unit with integrated functionality, allowing for simpler manufacturing of individual modules while maintaining overall system performance through modular assembly.
2Reliability
If conventional assemblies use multiple separate components requiring bonding and assembly, then acoustic damping is provided, but labor intensity and manufacturing cost increase
Solution Approach 1:
The compliance layer is integrated directly into the backing sheet structure rather than being applied as a separate component. This merging eliminates the need for additional bonding steps and assembly operations, making manufacturing easier while maintaining the acoustic damping function through the integrated structure.
Solution Approach 2:
The patent uses composite material structures where the backing sheet and compliance layer form an integrated composite structure. This allows the assembly to be manufactured as a single unit or pre-assembled module, reducing labor intensity while maintaining both acoustic damping performance and structural integrity.
3Strength
If conventional FAPs use thick plastic straps and multiple brackets for retention, then the assembly is securely held, but valuable axial space is consumed and aerodynamic performance is affected
Solution Approach 1:
The patent extracts and eliminates the thick plastic straps and multiple bracket components from the conventional assembly. Instead, it uses a streamlined retention system that achieves adequate holding strength with minimal axial space consumption, thereby preserving aerodynamic performance while maintaining assembly retention.
Solution Approach 2:
The integrated backing sheet with compliance layer acts as a flexible structural element that provides both retention and damping functionality in a thin profile. This eliminates the need for bulky mechanical fastening components while maintaining adequate assembly retention through the compliant structure.
4Reliability
If conventional assemblies require multiple manufacturing processes and materials, then acoustic damping is achieved, but production time and cost increase
Solution Approach 1:
The acoustic damping layers and structural layers are merged into integrated panels that can be manufactured in fewer steps. This merging reduces the total number of manufacturing processes required while maintaining the acoustic attenuation functionality through the integrated multi-layer structure.
Solution Approach 2:
The acoustic liner panels are pre-assembled and pre-integrated as complete modules before installation. This preliminary action allows for standardized manufacturing of self-contained units, reducing on-site assembly time and improving overall manufacturing productivity while ensuring acoustic damping performance.
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 modular design reduces manufacturing and installation time and costs, minimizes component complexity, and maximizes acoustic attenuation by optimizing space usage while maintaining aerodynamic integrity.
Implementation Method 1
the coupling element and the coupling portion are respectively formed to include a projection and a complementary shaped recess for mutual interlocking engagement
Implementation Method 2
The coupling element and/or coupling portion may include a compliant member enabling the interference fit
Data Source
AI summary
A method of lining a turbofan casing (30) with an array (32) of liner modules (34), including the steps of: providing a liner module (34); and providing a coupling element (48) on the casing for interlocking engagement with the liner module to maintain the liner module in position relative to the casing; and interlockingly engaging the liner module (34) and coupling element (48) by progressive movement of the liner module relative to the coupling element.