Movable Tooling for Composite Nacelle Cascade Manufacturing

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Solution Overview

Problem

Current methods for manufacturing thrust reverser cascades for aircraft nacelles using composite materials are expensive and limit the geometry of the cascades, failing to achieve aerodynamic profiles that are scalable and adaptable to the nacelle's performance.

Innovation Solution

A tooling system comprising first and second sole plates with movable tooling elements and peripheral bars that allow for the compression and shaping of composite materials, enabling the creation of apertured elements with geometries adapted to aerodynamic performances by allowing the tooling elements to slide and compress the material between the sole plates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual laying up of composite fabrics is used, then manufacturing flexibility is improved, but manufacturing cost increases and aerodynamic profile scalability deteriorates

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent replaces manual mechanical laying up operations with an automated thermocompression molding system. The molding machine automatically places composite fabrics, applies heat and pressure, and cures the material, eliminating manual labor while reducing costs through automation and process standardization.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses thermocompression molding to change the physical parameters (temperature and pressure) during manufacturing. By controlling these parameters, the process achieves scalable production of aerodynamic profiles with consistent quality, overcoming the limitations of manual methods while maintaining design flexibility through programmable process parameters.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If thermocompression molding with fixed tooling is used, then manufacturing cost is reduced, but geometric adaptability deteriorates due to draft requirements

Engineering Contradiction:

Improvemanufacturing costVSAvoidgeometric adaptability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent employs movable molding elements including sliding cores and adjustable peripheral bars that can change position during the molding process. This dynamic tooling system eliminates the need for fixed drafts in the part geometry, allowing complex aerodynamic profiles to be manufactured without compromising moldability, while maintaining cost-effective thermocompression molding.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If expandable rigid cores with mechanical expansion are used, then geometric control is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvegeometric controlVSAvoidtooling complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses simple, replaceable positioning elements such as spacing blocks and adjustable bars rather than complex mechanically expandable cores. These simpler tooling elements achieve sufficient geometric control for the application while being easier and cheaper to manufacture and replace, reducing overall tooling complexity and cost.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Ease of manufacture

If silicone cores that swell under heat are used, then manufacturing simplicity is improved, but geometric precision deteriorates due to uncontrolled expansion

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidgeometric precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces thermal expansion mechanisms (silicone cores) with mechanically controlled positioning systems. The movable bars and spacing elements provide precise geometric control through mechanical means, eliminating the uncontrolled thermal expansion issue while maintaining process simplicity through automated thermocompression molding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This method reduces manufacturing costs and allows for the production of apertured elements with geometries optimized for aerodynamic performance, improving the scalability and adaptability of thrust reverser cascades.

Implementation Method 1

The tooling elements are free to slide between the first and second sole plates in order to compress the material

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12122106B2Tool for manufacturing openwork elements such as cascades for aircraft nacelles and method using such a tool

Publication Date: 2024.10.22 SAFRAN NACELLES

AI summary

Tooling for manufacture of an apertured element made of a composite material includes first and second sole plates and tooling elements. Each sole plate is configured to be placed on either side of the apertured element to be manufactured. The tooling elements are placed between the first and second sole plates. The tooling elements include at least one core and peripheral bars. The core is configured to delimit a cell of the apertured element to be manufactured. The core is movable in translation along the first and second sole plates. The peripheral bars are placed on a periphery of the core and configured to delimit the apertured element to be manufactured. At least one peripheral bar is movable in translation along the first and second sole plates.