Oxide Matrix Composite Acoustic Panel Honeycomb Core
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Solution Overview
Problem
Existing acoustic panels for turbomachines, particularly aircraft turbojet engines, face challenges such as high mass and complexity due to the use of nickel-based alloys, limited mechanical resistance of composite materials with short fibers, and high production costs when using advanced materials like silicon carbide-based ceramic matrix composites.
Innovation Solution
A method for manufacturing composite acoustic panels using a honeycomb core made from composite materials with an oxide matrix and long oxide fibers, which involves forming first and second walls, creating a honeycomb core with cells, and sealing the ends with third and fourth walls, thereby enhancing mechanical resistance and reducing mass and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If nickel-based alloy is used to manufacture acoustic panels, then temperature resistance is improved, but mass increases significantly
Solution Approach 1:
The patent applies composite materials by combining oxide matrix (such as alumina) with oxide fibers (such as alumina or silica fibers) to create a ceramic matrix composite that provides both high temperature resistance and reduced mass compared to nickel-based alloys. This composite structure allows the panel to maintain mechanical integrity at temperatures above 700°C while being significantly lighter than traditional nickel-based alloy panels.
2Ease of manufacture
If composite materials with short fibers are used for honeycomb core, then manufacturing is simplified, but mechanical resistance decreases
Solution Approach 1:
The patent applies parameter changes by transitioning from short fibers to long fibers in the oxide fiber reinforcement. This parameter change significantly improves mechanical resistance while the manufacturing process remains feasible through established ceramic matrix composite fabrication techniques such as slurry injection, tape casting, or fabric impregnation followed by sintering.
3Strength
If silicon carbide-based ceramic matrix composites are used, then temperature resistance and mechanical strength are improved, but production cost increases significantly
Solution Approach 1:
The patent applies this principle by selecting more cost-effective oxide-based ceramic materials (such as alumina matrix with alumina or silica fibers) instead of expensive silicon carbide-based composites. These oxide ceramics provide sufficient mechanical strength and temperature resistance for the application while being significantly cheaper to manufacture, thus reducing production costs without compromising essential performance requirements.
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 proposed solution results in acoustic panels with improved mechanical resistance at temperatures above 700°C, lower mass compared to nickel-based alloy panels, and reduced production costs, while maintaining effective noise reduction capabilities.
Implementation Method 1
Panels made entirely of composite materials having an oxide matrix and long oxide fibers have a better mechanical resistance at temperatures above 700° C.
Implementation Method 2
The panels are usually made of titanium alloy. If it incorporates an acoustic treatment, which is generally carried out by a Helmholtz resonator-type structure, i.e. introduction between two skins 14 of a honeycomb core 12 on the basis of titanium strips forming the transverse partitions 16 of the cell 18.
Data Source
AI summary
A method for manufacturing a composite panel is described. The method includes producing a first wall, a second wall, a third wall and a fourth wall from composite materials including an oxide matrix and long oxide fibres; from the first and second walls, producing a cellular core including a plurality of cells, each cell including a first end and an opposing second end, covering the first and second ends of the cells of the cellular core with the third wall and the fourth wall, respectively, so as to close the ends of said cells.