Septumized Cellular Core Fabrication via Tool Wrapping
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Solution Overview
Problem
Current methods for septumizing honeycomb cores in acoustic treatments are time-consuming, labor-intensive, and decrease mechanical performance, as they require splitting the core or multiple steps in the lost wax process, or the use of automated robotic equipment to insert individual septum pieces.
Innovation Solution
A method where composite septums are formed and integrated into the honeycomb core cells during fabrication by wrapping composite sheets around tools, with the septums being affixed and cocured with the core, eliminating the need for separate septum installation steps and enhancing mechanical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual septum pieces are inserted using automated robotic equipment, then manufacturing precision is improved, but device complexity and productivity are worsened
Solution Approach 1:
The septum is pre-installed on the tool before the honeycomb core fabrication begins. This preliminary action eliminates the need for separate robotic insertion operations after core formation, thereby maintaining positioning precision while dramatically improving productivity by integrating septum installation into the core fabrication process itself
Solution Approach 2:
The septum installation process is merged with the honeycomb core fabrication process. By combining these two previously separate operations into one integrated process, the patent eliminates the need for complex automated robotic equipment while maintaining precision through the tool-based positioning method
2Ease of manufacture
If the core is split to install a septum layer, then ease of manufacture is improved, but strength and reliability are worsened
Solution Approach 1:
The septum is installed on the tool before the core is fabricated and before any splitting operations would be required. This preliminary installation eliminates the need to split the core later, thereby maintaining the core's structural integrity and strength while still achieving easy septum installation through the tool-integrated method
Solution Approach 2:
The need to split the core for septum installation is extracted/eliminated from the manufacturing process. By installing the septum on the tool beforehand, the patent removes the harmful splitting operation entirely, preserving core strength while maintaining ease of manufacture
3Ease of manufacture
If the lost wax process is used to create a buried septum, then ease of manufacture is improved, but loss of time and device complexity are worsened
Solution Approach 1:
The septum is installed on the tool before core fabrication begins, eliminating the need for the multi-step lost wax process including wax application, resin coating, curing, and laser perforation. This preliminary action dramatically reduces manufacturing cycle time while maintaining ease of septum installation
Solution Approach 2:
The patent skips through the multiple time-consuming steps of the lost wax process (wax application, resin floating, curing, laser perforation) by directly installing the septum on the tool beforehand. This skipping of intermediate steps dramatically reduces manufacturing cycle time while achieving the same result
Data Source
AI summary
A composite acoustic liner has a septumized cellular core. Septa are installed in the core as the individual core cells are being formed. Individual tools are used to both form the cells of the core and index the septa within the cells. The septa and the cellular core are cocured.