Thrust Reverser Cascade Segments Discrete Molding Assembly
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Solution Overview
Problem
The existing methods for manufacturing composite thrust reverser cascades are labor-intensive and expensive, particularly due to the need for hand layup and the use of flexible mandrels in closed-die or autoclave molding processes.
Innovation Solution
The method involves discretely molding first and second cascade segments with fiber reinforcement in a polymer matrix, where the second segment is bonded to the first segment and nested into it, allowing for the use of non-flexible tooling and reducing manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If closed-die or autoclave molding process with flexible mandrels is used to manufacture composite cascades, then structural integrity is achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The cascade is divided into multiple discrete segments that can be molded separately using simple, non-flexible tooling. These segments are then assembled together to form the complete cascade structure, eliminating the need for complex flexible mandrels while maintaining structural integrity through proper segmentation and assembly
Solution Approach 2:
The discrete cascade segments are nested within a mold cavity during assembly, with each segment fitting into a designated location. This nesting approach allows simple tooling to be used while achieving the complex three-dimensional cascade configuration through strategic placement and interlocking of segments
2Manufacturing precision
If hand layup process is used to manufacture composite cascades, then fiber reinforcement is properly positioned, but labor intensity and manufacturing time increase significantly
Solution Approach 1:
The fiber reinforcement is pre-positioned within the mold cavity before the polymer matrix is applied. This preliminary placement ensures proper fiber orientation and distribution without requiring labor-intensive hand layup processes, as the fibers are already in their final positions when the matrix is injected
Solution Approach 2:
The manual hand layup process is replaced with a mechanical injection molding process where the polymer matrix is injected under pressure to impregnate and bind the pre-positioned fiber reinforcement. This substitution eliminates manual labor while maintaining precise fiber positioning through the molding process itself
3Ease of manufacture
If discrete cascade segments are molded and assembled, then manufacturing cost and time are reduced, but assembly complexity increases
Solution Approach 1:
Multiple discrete cascade segments are merged into a single assembled structure through bonding or mechanical interlocking. The segments are designed with complementary features that simplify their combination, such as interlocking geometries or bonding surfaces, reducing the overall assembly complexity despite the modular approach
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
This approach reduces manufacturing time and expense by eliminating the need for flexible tooling and labor-intensive processes, while maintaining structural integrity through preconsolidated fabric and chopped fibers in a polymer matrix.
Implementation Method 1
Each of the cascade segments includes an array of vane segments and comprises fiber reinforcement in a polymer matrix
Implementation Method 2
The second cascade segment is bonded to the first cascade segment, and the second cascade segment is nested into the first cascade segment
Data Source
AI summary
Methods are provided for manufacturing a thrust reverser cascade. One of these methods includes providing a first cascade segment and providing a second cascade segment. The first cascade segment includes a first frame rail, a second frame rail and an array of first vane segments laterally between the first and the second frame rails. The second cascade segment includes an array of second vane segments. The second cascade segment is bonded laterally to and between the first and the second frame rails and transversely to the array of first vane segments. In another method, first and second cascade segments are discretely molded. Each of the cascade segments includes an array of vane segments and comprises fiber reinforcement in a polymer matrix. The second cascade segment is bonded to the first cascade segment and is nested into the first cascade segment.