Aircraft Nacelle Soundproof Panel Mold for Radial Alignment
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Solution Overview
Problem
The existing method of producing soundproof panels for aircraft turboshaft engines results in radial misalignment and aerodynamic interference due to separate manufacturing, leading to increased drag and gaps between panels.
Innovation Solution
A method involving the use of a single mold to produce both soundproof panels simultaneously, with each panel featuring an inner skin oriented towards the duct, where a honeycomb web and outer panel are positioned and cured together to reduce gaps and misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two soundproof panels are produced separately, then each panel can be manufactured independently, but radial misalignment and gaps occur between the panels
Solution Approach 1:
The patent merges the manufacturing process of two separate soundproof panels into a single mold operation. The mold contains two cavities positioned adjacent to each other, allowing both panels to be produced simultaneously in the same mold, ensuring radial alignment while maintaining independent panel structures.
Solution Approach 2:
The patent transitions from sequential production (one panel after another) to simultaneous production by utilizing the spatial dimension within a single mold. The two cavities are arranged side-by-side in the same mold plane, enabling parallel manufacturing that eliminates alignment issues between sequentially produced panels.
2Adaptability or versatility
If two soundproof panels are produced separately, then manufacturing flexibility is maintained, but aerodynamic interference and increased drag occur
Solution Approach 1:
By combining the production of both panels in a single mold with simultaneous curing, the patent eliminates gaps and misalignment between panels. This results in a smoother surface that reduces aerodynamic interference and drag, while the mold design still allows for flexible manufacturing through removable cavities or inserts.
Solution Approach 2:
The patent performs preliminary positioning and alignment of both panels within the mold before curing. The cavities are pre-configured in the mold to ensure precise radial alignment, and the panels are positioned and cured together in advance, preventing subsequent alignment issues that would cause aerodynamic problems.
3Manufacturing precision
If a single mold with two cavities is used, then radial misalignment is eliminated, but mold complexity increases
Solution Approach 1:
The patent segments the mold into two separate cavities within a single mold body. Each cavity can be independently designed and positioned to achieve precise radial alignment. The segmentation allows for simplified individual cavity designs while maintaining overall alignment through the unified mold structure.
Solution Approach 2:
The single mold serves multiple functions by containing two cavities that produce both soundproof panels simultaneously. This multi-functional mold design consolidates what would otherwise require two separate molds, reducing overall system complexity while maintaining manufacturing precision through a unified reference frame.
4Manufacturing precision
If panels are produced in the same mold, then gaps between panels are reduced, but production time for each panel increases
Solution Approach 1:
The patent implements continuous useful action by curing both panels simultaneously in the same mold during a single curing cycle. This eliminates the need for separate curing operations for each panel, maintaining continuous production flow while achieving precise alignment and gap reduction through the unified mold structure.
Solution Approach 2:
By merging the curing processes of both panels into a single simultaneous curing operation, the patent eliminates the time loss associated with sequential curing. The unified mold allows both panels to be cured together, reducing total production time while maintaining manufacturing precision through the combined curing process.
Data Source
AI summary
A method for manufacturing two soundproof panels of an aircraft nacelle including a duct. The manufacturing method includes a step of supplying a mold having, on a single face, a cavity for each soundproof panel, a step of producing, in the bottom of each cavity, an inner skin for being oriented towards the duct, and a curing step during which the elements present in the mold are cured in the mold. Such a method makes it possible to produce the two soundproof panels in the same mold, thus reducing the gaps between them after they have been positioned.