Thrust Reverser Cascade Composite Frame and Modular Vanes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional thrust reverser cascades in turbine engines, particularly those for medium to large turbofan engines, face limitations in structural integrity and manufacturing complexity, often relying on materials like cast aluminum or graphite/resin composites, which may not adequately address the demands of reverse thrust generation and maintenance.
Innovation Solution
A thrust reverser cascade design featuring a peripheral frame made from composite layup of woven fibers and resin, with plates and vanes manufactured using fiber-reinforced materials, allowing for increased structural capability and modular assembly, incorporating techniques like injection molding, pultrusion, and resin transfer molding to enhance strength and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional materials like cast aluminum or graphite/resin composites are used for thrust reverser cascades, then manufacturing experience and availability are improved, but structural integrity and strength under reverse thrust loads are insufficient
Solution Approach 1:
The patent applies composite materials by constructing the thrust reverser cascade from multiple layers of woven fiber (such as carbon fiber) and resin. This composite structure provides superior strength-to-weight ratio and structural integrity compared to traditional cast aluminum or graphite/resin composites, while still being manufacturable through established composite fabrication processes.
2Ease of manufacture
If traditional monolithic cascade designs are used, then manufacturing simplicity is maintained, but repairability and maintenance complexity are worsened
Solution Approach 1:
The patent applies segmentation by dividing the thrust reverser cascade into multiple discrete components including individual vanes, plates, and frame sections. These segmented components can be independently manufactured, inspected, and replaced. If one vane or plate is damaged, only that specific component needs to be replaced rather than the entire cascade assembly, significantly reducing maintenance complexity and repair time.
3Manufacturing precision
If uniform fiber length is used in composite materials, then manufacturing consistency is improved, but structural performance and strength are insufficient
Solution Approach 1:
The patent applies local quality by incorporating fibers of varying lengths within the composite structure. Different regions of the cascade can contain fibers optimized for their specific functional requirements - longer fibers in high-stress load-bearing areas for enhanced strength, and shorter fibers in areas requiring different mechanical properties. This localized optimization of fiber characteristics improves overall structural performance while maintaining manufacturing feasibility through controlled composite layup processes.
Data Source
AI summary
A thrust reverser cascade can include a peripheral frame having at least one side. At least one plate can be mounted to the at least one side and have a plurality of spaced grooves. In addition, a plurality of vanes can include corresponding terminal ends positioned in the plurality of spaced grooves.