Acoustic panels that include multi-layer facesheets
10720135 ยท 2020-07-21
Assignee
Inventors
Cpc classification
B29D24/005
PERFORMING OPERATIONS; TRANSPORTING
B64D2033/0206
PERFORMING OPERATIONS; TRANSPORTING
Y02T50/60
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B32B27/20
PERFORMING OPERATIONS; TRANSPORTING
B32B3/12
PERFORMING OPERATIONS; TRANSPORTING
International classification
B29C70/54
PERFORMING OPERATIONS; TRANSPORTING
B29C70/38
PERFORMING OPERATIONS; TRANSPORTING
B32B3/12
PERFORMING OPERATIONS; TRANSPORTING
B32B27/20
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Systems and methods are provided for fabricating acoustic panels. One embodiment is a method comprising acquiring a core of acoustic cells, and fabricating a facesheet covering the core by: dispensing a base layer of material atop the acoustic cells while leaving openings into each of the acoustic cells, covering the openings by applying a liner of porous material atop the base layer, dispensing a cap layer of material atop liner while leaving gaps in the cap layer over the acoustic cells, and fusing the cap layer to the liner by directly radiating laser energy onto locations where the cap layer has been dispensed.
Claims
1. A method comprising: acquiring a core of acoustic cells; and fabricating a facesheet covering the core by: dispensing a base layer of material atop the acoustic cells while leaving openings into each of the acoustic cells; covering the openings by applying a liner of porous material atop the base layer; dispensing a cap layer of material atop the liner, wherein the cap layer is shaped in a repeating pattern that exhibits gaps over the acoustic cells, each gap being aligned with an opening defined in the base layer; and fusing the cap layer to the liner by directly radiating laser energy solely onto the repeating pattern of the cap layer.
2. The method of claim 1 wherein: fusing the cap layer to the liner further comprises fusing the liner to the base layer.
3. The method of claim 2 wherein: the core of acoustic cells is thermoplastic; and the method further comprises fusing the base layer to the core of acoustic cells by directly radiating laser energy onto locations where the base layer has been dispensed.
4. The method of claim 1 wherein: fusing the cap layer comprises directly radiating laser energy only onto locations at which the cap layer overlaps the liner.
5. The method of claim 4 wherein: fusing the cap layer causes the liner to become non-porous at locations where laser energy is directly applied.
6. The method of claim 1 wherein: dispensing the cap layer forms the gaps such that a width of each gap parallel to expected airflow is less than a height of each gap perpendicular to expected airflow.
7. The method of claim 1 further comprising: printing the base layer via three dimensional (3D) printing techniques.
8. The method of claim 1 further comprising: printing the liner via three dimensional (3D) printing techniques.
9. The method of claim 1 wherein: material for the base layer and the cap layer comprises Carbon Fiber Reinforced Polymer (CFRP) thermoplastic; and material for the liner comprises thermoplastic.
Description
DESCRIPTION OF THE DRAWINGS
(1) Some embodiments of the present disclosure are now described, by way of example only, and with reference to the accompanying drawings. The same reference number represents the same element or the same type of element on all drawings.
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DESCRIPTION
(14) The figures and the following description illustrate specific exemplary embodiments of the disclosure. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the disclosure and are included within the scope of the disclosure. Furthermore, any examples described herein are intended to aid in understanding the principles of the disclosure, and are to be construed as being without limitation to such specifically recited examples and conditions. As a result, the disclosure is not limited to the specific embodiments or examples described below, but by the claims and their equivalents.
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(16) Further details of the features of acoustic panel 200 are described with regard to
(17) Further discussion of acoustic panel 200 will be made with regard to
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(19) End effector 524 further includes laser 526, which emits beam 527 of laser energy 599 (e.g., infrared (IR) heat energy). This laser energy 599 is utilized to fuse different layers of thermoplastic together. In this embodiment, laser 526 follows dispenser 528 as AFP machine 520 continues in a direction of travel 598. Hence, laser 526 is capable of directly radiating laser energy 599 onto locations (L) that have just been laid-up or printed in order to heat thermoplastic material 597 to a fusing temperature (e.g., a melting temperature). This facilitates rapid fusing in order to form an acoustic panel 200
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(21) As shown in
(22) The final component laid-up by AFP machine 520 is cap layer 532, which comprises thermoplastic CFRP. Like base layer 536, cap layer 532 is laid-up in a pattern that leaves gaps/openings. This pattern may include openings which are shaped and arranged in order to provide low drag over acoustic cells 240 (i.e., a smooth(er) aerodynamic surface). The carbon fiber in cap layer 532 provides mechanical support to liner 534 without altering the fundamental acoustic properties of facesheet 530. The patterns described herein may follow the contours of walls 230 at core 550, and are illustrated with regard to
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(24) With the physical features of facesheet 530 described above, a method describing illustrative details of the operation of system 500 of
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(26) An acoustic panel 200 having pattern 700 may therefore include a core 550 comprising multiple cells 240 of thermoplastic having walls that are fused together, and a facesheet 530 fused to a surface 538 of core 550. The facesheet 530 includes multiple openings 600 through which sound waves enter the cells, and a porous liner 534 within the openings provides acoustic control by keeping a majority of airflow across the openings connected and laminar, thereby reducing drag. Liner 534 is fused with the rest of facesheet 530, but remains porous.
(27) Using the acoustic paneling described above, a method may be used for performing acoustic control of jet engine noise via an acoustic panel. This is illustrated with regard to method 800 of
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(29) In step 852, system 500 acquires core 550 of acoustic cells 240. Core 550 may comprise a linear sheet of cells arranged in any suitable pattern (e.g., a tessellating pattern of hexagonal cells, triangular cells, square cells, etc.). In this embodiment, core 550 is open in that it has neither a backing sheet nor a facesheet. Core 550 may therefore be made as a single extruded piece of thermoplastic, or may be 3D printed thermoplastic. Core 550 may be acquired by either placing core 550 in a desired location with respect to system 500, or by actively printing core 550 via system 500. With core 550 acquired, a septum 400 may be inserted into each cell 240, or may even be 3D printed into each cell via dispenser 528.
(30) In embodiments where dispenser 528 is a 3D printing device, dispenser 528 may 3D print individual tows (comprising thermoplastic and carbon fiber) via a separate nozzle than for components which comprise only thermoplastic. When printing thermoplastic materials that are porous in nature (e.g., where a specific level of porosity is desired in order to provide acoustic performance (enabling acoustic energy to freely enter cells 240) while also ensuring smooth properties that enhance aerodynamics), a temperature of the dispensing nozzle, an amount of material ejected, an amount of ejection pressure, and/or a cooling time may be adjusted in order to fine tune the porosity to desired characteristics.
(31) With cells 240 ready for creation of a facesheet, system 500 initiates fabrication of a facesheet 530 covering core 550 of acoustic cells 240 (step 854). The facesheet includes three separate components. The first component is base layer 536, which is dispensed atop acoustic cells 240 by dispenser 528, and leaves openings 600 over cells 24 which allow acoustic energy to freely enter cells 240 (step 856). After base layer 536 has been applied by dispenser 528, laser 526 may fused base layer 536 to core 550 by radiating beam 527 of laser energy directly onto locations at which layer 536 has been dispensed. This heats thermoplastic polymer within base layer 536, causing fusing (e.g., via melting) between base layer 536 and core 550.
(32) Next, cells 240 are covered by liner 534, which is applied atop base layer 536 (step 858). In one embodiment, liner 534 is applied as a continuous layer that covers gaps 600 as well as base layer 536. In one embodiment, liner 534 is a prefabricated sheet of thermoplastic having a known porosity (e.g., a percent open area of twenty to eighty percent). In further embodiments, liner 534 is printed via dispenser 528. Liner 534 attenuates acoustic energy while still enabling acoustic energy to flow into cells 240 for further attenuation. However, since liner 534 is porous, it may be desirable to enhance the structural strength of facesheet 530 (e.g., in order to ensure that materials impacting facesheet 530 do not remove substantial amounts of material from facesheet 530.
(33) In order to ensure that desired levels of structural strength are achieved for facesheet 530, controller 510 directs dispenser 528 to dispense cap layer 532 atop liner (step 860). Cap layer 532 is laid up in the same pattern as base layer 536. Because cap layer 532 includes carbon fiber, cap layer 532 is substantially stronger than liner 534.
(34) With the components of facesheet 530 fully in place, controller 510 operates laser 526 to radiate laser energy (e.g., IR heat) onto locations where cap layer 532 intersects liner 534 (step 862). That is, heat applied via beam 527 of laser energy from laser 526 is sufficient to cause cap layer 532 to fuse with underlying components of facesheet 530 (e.g., liner 534 and base layer 536). Controller 510 may perform this step substantially concurrently with the dispensing of layer 532, such that tows of CFRP are fused via laser 526 immediately after they are laid up. Alternatively, controller 510 may cause laser 526 to perform fusing via an entirely separate run from the run in which thermoplastic CFRP is dispensed. In either case, laser 526 is operated in such a manner that no laser energy is directly radiated onto liner 534 in gaps 600, as this could cause liner 534 to melt and become non-porous in such gaps. Thus, laser 526 selectively applies heat only to locations at which cap layer 532 overlaps liner 534. As an additional step, a continuous backing sheet may be applied (e.g., via 3D printing or AFP tow layup) in order to complete the fabrication of cells 240.
(35) Method 850 provides an advantage over prior techniques in that it allows for rapid fabrication of large sets of acoustic cells. Furthermore, in embodiments where 3D printing techniques are utilized, large sets of acoustic cells may be fabricated to fit complex 3D contours, such as those found along the interior of an engine cowling.
EXAMPLES
(36) In the following examples, additional processes, systems, and methods are described in the context of acoustic paneling for aircraft.
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(39) Referring more particularly to the drawings, embodiments of the disclosure may be described in the context of an aircraft manufacturing and service method 1100 as shown in
(40) Each of the processes of method 1100 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.
(41) As shown in
(42) As already mentioned above, apparatus and methods embodied herein may be employed during any one or more of the stages of the production and service method 1100. For example, components or subassemblies corresponding to production stage 1108 may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft 1102 is in service. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the production stages 1108 and 1110, for example, by substantially expediting assembly of or reducing the cost of an aircraft 1102. Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized while the aircraft 1102 is in service, for example and without limitation, to maintenance and service 1116. For example, the techniques and systems described herein may be used for steps 1106, 1108, 1110, 1114, and/or 1116, and/or may be used for airframe 1118 and/or interior 1122. These techniques and systems may even be utilized for systems 1120, including for example propulsion 1124, electrical 1126, hydraulic 1128, and/or environmental 1130.
(43) In one embodiment, acoustic panel 200 comprises a portion of airframe 1118, and is manufactured during component and subassembly manufacturing 1108. Acoustic panel 200 may then be assembled into an aircraft in system integration 1110, and then be utilized in service 1114 until wear renders acoustic panel 200 unusable. Then, in maintenance and service 1116, acoustic panel 200 may be discarded and replaced with a newly manufactured acoustic panel 200. Enhanced automated fabrication systems such system 500 of
(44) Any of the various control elements (e.g., electrical or electronic components) shown in the figures or described herein may be implemented as hardware, a processor implementing software, a processor implementing firmware, or some combination of these. For example, an element may be implemented as dedicated hardware. Dedicated hardware elements may be referred to as processors, controllers, or some similar terminology. When provided by a processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared. Moreover, explicit use of the term processor or controller should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, without limitation, digital signal processor (DSP) hardware, a network processor, application specific integrated circuit (ASIC) or other circuitry, field programmable gate array (FPGA), read only memory (ROM) for storing software, random access memory (RAM), non-volatile storage, logic, or some other physical hardware component or module.
(45) Also, a control element may be implemented as instructions executable by a processor or a computer to perform the functions of the element. Some examples of instructions are software, program code, and firmware. The instructions are operational when executed by the processor to direct the processor to perform the functions of the element. The instructions may be stored on storage devices that are readable by the processor. Some examples of the storage devices are digital or solid-state memories, magnetic storage media such as a magnetic disks and magnetic tapes, hard drives, or optically readable digital data storage media.
(46) Although specific embodiments are described herein, the scope of the disclosure is not limited to those specific embodiments. The scope of the disclosure is defined by the following claims and any equivalents thereof.