Resonator Core Panel Manufacturing for Aircraft Cabin Noise Reduction
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Solution Overview
Problem
There is a need for low-cost acoustic transmission loss panels that can effectively reduce aircraft cabin noise and provide thermal insulation, as existing paneling is insufficient in many instances.
Innovation Solution
A continuous manufacturing method for acoustic panels with a resonator core attached to a sidewall, featuring interconnected resonator chambers that attenuate sound through a dynamic system of mass and stiffness, and are formed from a single sheet using rollers with protrusions and dimples to create specific chamber shapes and holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional paneling is used, then the structure is simple, but noise reduction and thermal insulation are insufficient
Solution Approach 1:
The patent employs a resonator core with a porous lattice structure comprising interconnected struts and cells. This porous configuration enables acoustic attenuation through sound wave interaction with the lattice structure and provides thermal insulation by trapping air pockets within the cellular architecture, thereby addressing both noise reduction and thermal protection requirements
Solution Approach 2:
The acoustic panel utilizes a composite structure combining a skin layer with an integrated resonator core. The resonator core itself is a composite of struts and cellular elements forming a lattice structure. This composite approach enables simultaneous achievement of structural integrity, acoustic attenuation, and thermal insulation properties that cannot be obtained with conventional homogeneous paneling
2Object-affected harmful factors
If complex acoustic elements are added to improve noise reduction, then acoustic performance improves, but manufacturing cost and complexity increase
Solution Approach 1:
The patent merges the resonator core formation with the skin forming process into a single integrated operation. The patterned film is thermally formed between patterned rollers that simultaneously create both the skin curvature and the resonator core lattice structure. This consolidation eliminates separate manufacturing steps, reducing production complexity and cost while maintaining acoustic performance
Solution Approach 2:
The patterned rollers serve multiple functions: they form the skin layer, create the resonator core lattice structure, define cell geometry, and establish interconnections between cells. This multi-functionality reduces the number of manufacturing components and steps required, simplifying production while achieving complex acoustic attenuation functionality
3Object-affected harmful factors
If a resonator core with interconnected chambers is created, then acoustic attenuation improves, but manufacturing time and process complexity increase
Solution Approach 1:
The patent implements a continuous manufacturing process where the skin and resonator core are formed simultaneously in a single thermal forming operation. The patterned film passes continuously through heated zones between patterned rollers, enabling uninterrupted production of acoustic panels with integrated resonator cores, thereby maintaining high productivity while achieving superior sound transmission loss
4Manufacturing precision
If thermal forming is used to create resonator chambers, then chamber shape precision improves, but energy consumption increases
Solution Approach 1:
The thermal forming process is segmented into multiple zones with different temperature profiles. The film passes through sequentially heated sections that progressively form different portions of the resonator chambers. This segmentation allows precise control of chamber geometry while distributing thermal energy input efficiently, reducing total energy consumption compared to uniform high-temperature processing
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 method produces lightweight, efficient panels that effectively attenuate noise and provide thermal insulation, enhancing passenger comfort and reducing sound transmission.
Implementation Method 1
receiving the roll of the film includes unwinding and heating the film above a glass transition temperature of the film
Implementation Method 2
the first roller and the second roller cool the film below the glass transition temperature
Implementation Method 3
interconnected resonator chambers that attenuate sound through a dynamic system of mass and stiffness
Implementation Method 4
pulling a vacuum on the film in the plurality of dimples
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A method (800; 900) is described. The method (800; 900) is a continuous manufacturing method of an acoustic transmission loss panel resonator core (206). The acoustic panel (200) is a double-wall panel construction with two sidewall panels and a resonator core (206). The resonator core (206) is formed from a roll (801) of film (803). One or more rollers (805) form interconnected resonator chambers (504) in the film (803). The resonator chambers (504) are in a rectangular lattice shape. The resonator chambers (504) are continuously formed from a single sheet and then bonded to the second sidewall (204). The resonator core (206) is then attached between first and second sidewalls (202, 204). The resonator core (206) defines an air gap between the resonator core (206) and the first sidewall (202).