Thrust Reverser Grille Manufacturing via Injection Molding
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Solution Overview
Problem
The manufacturing of 'cascade' type thrust reverser grilles for aircraft jet engines is complex and costly due to the need for multiple manual steps and expensive tooling, particularly in assembling components like vanes and strongbacks, which requires complex and reusable mandrels.
Innovation Solution
A method involving the manufacturing of first components with continuous fibers and second components with discontinuous fibers, arranged to form a comb-shaped structure, which are consolidated and secured to a frame, reducing the need for complex assembly steps and tools, and allowing for cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional multi-step manufacturing method with separate component assembly is used, then manufacturing precision and component strength are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate manufacturing steps into a single injection molding process. The mold includes a first cavity for the strongback, a second cavity for the vane, and a third cavity for the insert, allowing all components to be manufactured and assembled in one operation. This eliminates the need for separate manufacturing and assembly steps while maintaining component strength through integrated construction.
2Manufacturing precision
If complex assembly steps with multiple components are used, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent incorporates preliminary action by pre-forming the insert with specific geometric features (protrusions and recesses) that automatically align and secure the vane to the strongback during the injection molding process. The insert is prepared in advance with these features, so that when all components are injected into the mold cavities, the assembly occurs automatically without requiring post-assembly operations, thus maintaining precision while improving productivity.
3Manufacturing precision
If expensive reusable mandrels and tooling are used, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive reusable mandrels with a disposable insert made of paper or cardboard. This insert is placed in the mold cavity before injection and serves as a temporary support structure that defines the geometry and ensures precision during manufacturing. After the component is formed, the disposable insert is easily removed and discarded, eliminating the need for costly reusable tooling while maintaining manufacturing precision.
4Manufacturing precision
If manual assembly steps are used, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated injection molding process. The mold mechanism automatically injects molten material into the cavities, forms all components, and assembles them through the pre-designed geometric features of the insert. This mechanical automation eliminates manual assembly steps, maintaining precision through controlled injection while significantly reducing the time required for manufacturing.
Data Source
AI summary
The invention proposes a method for manufacturing a grille for a cascade type thrust reverser, of a jet engine, said method including the following steps:a) manufacturing a first component comprising long fibres, pre-impregnated by a thermoplastic or thermosetting resin; b) manufacturing, together with step a), a series of second components each including discontinuous fibres, pre-impregnated by a thermoplastic or thermosetting resin, step b) being carried out such that the second components are, on the one hand, arranged to transversally with respect to a longitudinal direction of the first component on at least one side of the first component and, on the other hand, spaced from one another according to this longitudinal direction, so as to form a comb-shaped structure, wherein the second components are consolidated to the first component.