Thrust Reverser Door Grid Structure Segmentation
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Solution Overview
Problem
Conventional methods of manufacturing thrust reverser doors for gas turbine engines are time-consuming and expensive, requiring high stiffness and complex curvatures while transferring loads effectively.
Innovation Solution
The use of a grid structure with an orthogrid or isogrid configuration formed from thermoplastic materials, where the grid structure is either overmolded onto the cover plate body or backskin, and then welded or bonded to the other component, providing improved stiffness and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional methods are used to manufacture thrust reverser doors with high stiffness and complex curvatures, then the structural requirements are met, but the manufacturing time and cost increase
Solution Approach 1:
The thrust reverser door is divided into separate components: a cover plate, a backskin, and a grid structure. These segments are manufactured independently and then assembled together, allowing each component to be optimized and manufactured more efficiently while maintaining the overall structural integrity and stiffness requirements of the complete door assembly.
Solution Approach 2:
The invention employs composite construction by combining the cover plate, backskin, and grid structure into a unified assembly. This composite approach allows each component to be made from materials optimized for its specific function, achieving the required stiffness and complex curvature requirements while reducing manufacturing time compared to conventional monolithic construction methods.
2Strength
If conventional methods are used to manufacture thrust reverser doors with high stiffness and complex curvatures, then the structural requirements are met, but the manufacturing cost increases
Solution Approach 1:
By segmenting the door into manufacturable components (cover plate, backskin, grid structure), each part can be produced using optimized processes and standard manufacturing techniques, reducing tooling costs and material waste compared to conventional methods that require expensive, specialized equipment to produce the entire door as a single complex piece.
Solution Approach 2:
The composite construction allows each component to be manufactured from materials and processes optimized for its specific requirements, rather than using a single expensive material or process for the entire door. This reduces overall manufacturing cost while maintaining the necessary stiffness and complex curvature performance.
3Strength
If a grid structure is added to the thrust reverser door, then the stiffness is enhanced, but the device complexity increases
Solution Approach 1:
The grid structure is implemented as a separate, modular component that can be independently manufactured and then assembled to the cover plate and backskin. This segmentation allows the complex grid pattern to be produced using standardized processes without requiring the entire door assembly process to be equally complex, as each component can be optimized independently.
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 results in thrust reverser doors with enhanced stiffness while reducing manufacturing time and cost, enabling more efficient production of complex components.
Implementation Method 1
mounting the second side of the cover plate body to the interior surface of the backskin with the grid structure includes induction welding the grid structure to one or both of the cover plate body and the backskin
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A thrust reverser door (58) includes a backskin (66) including an interior surface (68) and an exterior loft surface (62). The thrust reverser door (58) further includes a cover plate (74) including a cover plate body (88) having a first side (76) and a second side (78) opposite the first side (76). The thrust reverser door (58) further includes a grid structure (80) mounted to the second side (78) of the cover plate body (88) and the interior surface (68) of the backskin (66).