Nested Thrust Reverser Seals for Pressure-Tolerant Aircraft Sealing
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Solution Overview
Problem
Existing aircraft seal systems, such as bulb seals, face issues with air leakage and premature failure due to pressure fluctuations, which cause over-compression or under-compression, leading to creasing, wear, and reduced operational life, and they often have a small contact surface area, making them ineffective in maintaining a tight seal during aircraft operation.
Innovation Solution
The proposed seal system includes a first seal with a bulb-style cross-sectional shape and a second seal with a cup-style cross-sectional shape, where the second seal partially collapses to form a pocket around the first seal, increasing the contact surface area and providing a more effective seal by distributing the sealing force over a larger area, thus preventing air leakage and fire containment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a bulb seal is used to seal the gap between thrust reversers, then the seal provides a simple structure and ease of manufacture, but the seal has a small contact surface area leading to over-compression, under-compression, creasing, wear, and premature failure
Solution Approach 1:
The seal system is divided into multiple independent seal elements (first seal and second seal) with different cross-sectional shapes. Each seal element has specific geometric features designed to work together, creating multiple contact points and distributing sealing forces across a larger surface area, thereby preventing over-compression and wear while maintaining manufacturing simplicity
Solution Approach 2:
The first seal and second seal are positioned nested relative to each other at the thrust reverser interface. The seals are arranged so that they engage sequentially, with each seal providing a layer of sealing protection. This nested configuration increases the effective contact surface area without significantly increasing the overall size or complexity of the sealing system
2Device complexity
If a bulb seal is used to seal the gap between thrust reversers, then the structure is simple, but the seal becomes over-compressed or under-compressed due to pressure fluctuations, reducing operational life
Solution Approach 1:
The invention changes the geometric parameters of the seal elements by using different cross-sectional shapes (first seal with one cross-sectional shape, second seal with another). This parameter variation allows the seals to respond differently to pressure fluctuations, with each seal's specific geometry providing optimal deformation characteristics that prevent over-compression and extend operational life while maintaining relatively simple structures
3Volume of moving object
If a seal has a small contact surface area, then the seal structure is compact, but the seal is ineffective in maintaining a tight seal during aircraft operation due to pressure fluctuations
Solution Approach 1:
The invention transitions from a single-dimension sealing approach to a multi-dimensional sealing strategy by employing two seals with different cross-sectional shapes arranged in a nested configuration. This dimensional approach allows the seals to engage with the thrust reverser interface from multiple geometric perspectives, creating extensive contact surface area across different planes and directions, thereby achieving reliable sealing without significantly increasing overall seal volume
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 seal system significantly increases the operational life of seals by maintaining a tight seal over a larger range of relative displacements without becoming over-compressed, providing a more effective barrier against air leakage and fire containment, and is tolerant to defects and deformations.
Implementation Method 1
The second seal having a second cross-sectional shape different than the first cross-sectional shape. The second seal is to receive at least a portion of the first seal in response to the first seal engaging the second seal.
Implementation Method 2
At least a portion of the second sealing body to deform and wrap around at least a portion of the first sealing body in response to the first seal engaging the second seal.
Data Source
AI summary
Seal systems for aircraft are disclosed. An example seal system includes a first seal to couple to a first thrust reverser portion, the first seal having a first cross-sectional shape. A second seal is to couple to a second thrust reverser portion opposite the first seal. The second seal having a second cross-sectional shape different than the first cross-sectional shape. The second seal is to receive at least a portion of the first seal in response to the first seal engaging the second seal.