One-Piece Nacelle Plenum Panels for Active Laminar Flow Control

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Solution Overview

Problem

Existing aircraft engine nacelles experience increased drag due to turbulent airflow, which increases fuel consumption, and existing laminar flow control systems are either inefficient or complex.

Innovation Solution

An active laminar flow control system with a one-piece panel and pre-installed adhesive fasteners, coupled to the outer skin via stiffeners, creating plenums for improved airflow management and reducing drag.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing laminar flow control systems are used, then turbulent airflow is reduced, but the systems are either inefficient or complex

Engineering Contradiction:

Improvelaminar flow control efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system divides the nacelle inlet surface into multiple discrete panels, each independently capable of generating plenums for laminar flow control. This segmentation allows the complex function of laminar flow control to be distributed across simpler, modular units, reducing overall system complexity while maintaining effectiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The panel structure serves multiple functions simultaneously: it acts as the nacelle inlet surface, contains embedded fasteners for attachment, creates plenums for airflow management, and provides structural support. This multi-functionality eliminates the need for separate components, reducing system complexity while maintaining laminar flow control efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If a one-piece panel with pre-installed adhesive fasteners is used, then ease of installation is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveinstallation easeVSAvoidpanel manufacturing precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The adhesive fasteners are pre-installed onto the panel during manufacturing, and the panel is designed as a one-piece structure with integrated features. This preliminary preparation of attachment features simplifies the installation process to a single placement operation, significantly improving ease of installation while the fasteners themselves accommodate normal manufacturing tolerances.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The adhesive fasteners utilize adhesive bonding parameters that are tolerant of normal manufacturing variations in panel dimensions and surface flatness. The adhesive material properties and bonding process are selected to provide sufficient tolerance for manufacturing precision variations while ensuring secure attachment.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP3628596B1Active laminar flow control plenum panel arrangements and installation methods

Publication Date: 2025.10.29 ROHR INC

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AI summary

A panel for an active laminar flow control arrangement may comprise a longitudinal wall (434) and one or more division walls (428) extending from the longitudinal wall (434) and extending between the first end (491) and the second end (492). The panel may be coupled to a nacelle outer skin (312) via a plurality of adhesive fasteners (326, 322) preinstalled onto an inner surface (314) of the outer skin (312) and onto stiffeners (382) and/or stringers (384) associated with the outer skin (312).