Jet Engine Thrust Reverser Cascade Assembly Using Thermoplastic Compression Molding
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Solution Overview
Problem
The fabrication of cascade grid panels for jet engine thrust reversers is time-consuming, labor-intensive, and expensive due to the use of fiber-reinforced thermoset resins requiring multiple processing steps and specialized equipment, leading to high production costs and complexity.
Innovation Solution
A cascade assembly for a jet engine thrust reverser is designed using compression molding of thermoplastic materials with simplified mold designs, featuring two separate cascades with straight and curved sections, allowing for the use of molds with fewer parts, reducing labor and time, and enabling efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fiber reinforced thermoset resins are used to fabricate cascade grid panels, then the structural integrity and performance are maintained, but the fabrication process becomes time-consuming, labor-intensive, and expensive
Solution Approach 1:
The patent changes the material parameter from thermoset resin to thermoplastic material, fundamentally altering the fabrication process. Thermoplastics can be molded and formed more efficiently without requiring complex multi-step processes like hand layup, compression molding, and post-curing. This material substitution maintains structural integrity while dramatically improving fabrication efficiency and reducing labor intensity
Solution Approach 2:
The patent extracts and eliminates the need for specialized equipment and multiple processing steps associated with thermoset resin fabrication. By using thermoplastic materials, the complex sequence of operations (thawing prepreg, pre-curing strongbacks, hand layup, compression molding, post curing) is replaced with simpler forming processes, removing the bottleneck of fabrication complexity
2Manufacturing precision
If multiple processing steps and specialized equipment are used for cascade fabrication, then the structural quality is ensured, but the production cost and complexity increase
Solution Approach 1:
The patent changes the material parameter from thermoset resin to thermoplastic material, fundamentally altering the fabrication process. Thermoplastics can be molded and formed more efficiently without requiring complex multi-step processes like hand layup, compression molding, and post-curing. This material substitution maintains structural integrity while dramatically improving fabrication efficiency and reducing labor intensity
Solution Approach 2:
The patent extracts and eliminates the need for specialized equipment and multiple processing steps associated with thermoset resin fabrication. By using thermoplastic materials, the complex sequence of operations (thawing prepreg, pre-curing strongbacks, hand layup, compression molding, post curing) is replaced with simpler forming processes, removing the bottleneck of fabrication complexity
3Manufacturing precision
If traditional mold designs with many parts are used for compression molding, then the cascade geometry is accurately formed, but the labor and time requirements increase
Solution Approach 1:
The patent divides the cascade structure into two separate cascades (inflow cascade and outflow cascade) with distinct functional zones. This segmentation allows each cascade to be molded independently using simpler mold designs, reducing the number of mold parts required. The straight and curved sections are strategically positioned to enable efficient molding while maintaining accurate cascade geometry, significantly reducing production time compared to traditional single-piece molding approaches
Data Source
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AI summary
A cascade assembly for a jet engine thrust reverser comprising an inflow cascade, an outflow cascade, and fasteners. The inflow cascade has a plurality of inflow vanes, a plurality of inflow strongbacks, and a front inflow flange. The outflow cascade has a plurality of outflow vanes, a plurality of outflow strongbacks, and a front outflow flange, wherein each of the plurality of outflow strongbacks are parallel to each other. The fasteners extend through the front inflow flange and the front outflow flange.