Patent Application
20220024555
The present invention relates generally to aircraft construction, and, more specifically, to noise suppression therein.
Commercial aircraft typically have large cabins for maximizing passenger carrying capability, and it is a paramount objective to minimize noise during aircraft flight for passenger comfort.
Aircraft noise, or sound, is generated during operation from articulation of the landing gear or flaps, engine operation, lavatories, and other sources and can be objectionable to the passengers.
Sandwich panel construction methods are used extensively throughout aircraft manufacturing for interior cabinets, flooring, sidewalls, stowage bins, and other components.
A composite sandwich panel typically includes inner and outer skins with a lightweight core adhered between the skins This forms a stiff and strong structural panel with correspondingly little weight. This sandwich construction is utilized throughout aircraft manufacturing, but has limited or no acoustic abatement effectiveness, and can even promote transmission of undesirable noise.
Many original equipment manufacturers (OEMs), or airframers, and their customer Airlines seek to reduce noise transmission throughout the cabin by typically adding sound attenuation features to various aircraft components including the walls, floors, and cabinets.
Adding noise abatement features can therefore increase the complexity, cost, and weight of an aircraft, and may even reduce available space for passengers and cargo.
Accordingly, it is desired to provide an improved aircraft structural panel having inherent sound attenuation features while minimizing associated complexity, cost, and weight.
A method of making an aircraft acoustic structural panel begins with preforming a core honeycomb laminate having preformed foam bonded inside cells by a distinct adhesive. The core laminate is then stacked between opposite top and bottom structural outer laminates The stacked core laminate and outer laminates are then compressed together under heat and pressure into a unitary structural panel having the core laminate integrally bonded between outer skins.
The invention, in accordance with preferred and exemplary embodiments, together with further objects and advantages thereof, is more particularly described in the following detailed description taken in conjunction with the accompanying drawings in which:
Illustrated in
The panel 10 is rectangular with a length L along the longitudinal axis X, and a width W along the transverse axis Y. The panel 10 is typically large with a length L of about 244 cm and a width W of about 122 cm, and may be specifically configured and sub-divided for various structural purposes in aircraft construction which typically requires high strength and structural rigidity with minimal weight.
In many aircraft-specific configurations disclosed above, noise or sound attenuation or abatement is also desired in the panel without substantially increasing its size, weight, or manufacturing costs.
A significant feature in the panel 10 shown in
The preformed honeycomb laminate 12 is stacked vertically between opposite top and bottom structural outer laminates 16, 18 and suitably compressed together under heat and pressure into the final unitary structural panel 10 having the core honeycomb laminate 12 integrally bonded between outer and inner skins 20,22.
The foam layer 3 is stacked atop a thermally curable adhesive film layer 2 and in turn also stacked atop a center or core honeycomb 1, and then suitably compressed together under pressure and heat to thermally bond the foam 3 inside the honeycomb cells 14 to preform the honeycomb laminate 12.
In the exemplary configuration shown in
The sidewall strips 24 are transversely spaced apart to define alternating hexagonal cells 14 suitably joined or bonded together at common sidewalls having a combined thickness of 2t.
This is shown schematically in
The acoustic foam layer 3 is preferably obtained in this way from a commercial supplier, instead of forming it de novo or in situ to ensure suitable material properties while minimizing complexity and cost of fabrication. One commercial supplier can provide the foam layer 3 with suitable uniform thickness F, and a length matching that of the desired panel, eg 244 cm, but with a width W/2 of about half the width W of the desired panel, eg about 61 cm, in which case the foam layer 3 may be preformed or supplied by using two commercially available half-strips (W/2) arranged side-by-side.
In the exemplary configuration shown in
In this way, the sharp honeycomb cells 14 cut the foam layer 3 in the fashion of an annular cookie cutter under suitable heating and compression to fill each cell 14 with a corresponding portion of the original foam layer, which is suitably bonded and sealed inside each cell 14 by respective portions of the adhesive layer 2.
The adhesive layer 2 is preferably provided in thin film form matching the total surface area of the rectangular core honeycomb 1 and foam layer 3, and the adhesive is also thermally setting. In this way, the foam 3 and adhesive 2 can be preferentially selected for ensuring that the sharp cells 14 can in fact cut the foam and adhesive into the corresponding foam plugs to fill each cell 14 under elevated temperature, without otherwise damaging or buckling the cells 14 or their thin and fragile sidewalls 24.
After pressing under heat, the so preformed core laminate 12 is allowed to cool to room temperature, with the thermally cured adhesive 2 securely bonding and sealing the foam plugs inside the multitude of honeycomb cells 14.
In the exemplary embodiment shown in
The left side of
In
In this way, the top press plate 28 ensures that the top of the foam is pressed substantially flush or even with the planar top surface of the cells 14, even after removal of the plate 28. The double-thickness of the initial foam layer 3 ensures that each of the honeycomb cells 14 is filled with foam substantially completely.
In one embodiment tested, the foam plugs substantially filled the cells about 80% to about 100% in view of the random nature of foam cutting over the multitude of cells 14 contained in the large core honeycomb 1, with the bottom of at least some of the cells having corresponding small voids 32 devoid of foam mostly around the perimeter of the hexagonal cell where sidewall friction prevents complete insertion of the foam to the bottom of the cells.
The resulting so preformed core honeycomb laminate 12 therefore includes foam 3, in plug form, securely adhesively bonded into each of the multitude of hexagonal cells 14 for providing effective acoustic or noise abatement or suppression. This configuration creates one form of muffler to dissipate acoustic energy or noise.
In a preferred configuration, the honeycomb 1 is metal, such as aluminum, with thin sidewalls 24 being sufficiently sharp to cut the foam layer 3 during the compression thereof.
Correspondingly, the preferred foam layer 3 is sufficiently soft for being readily cut by the honeycomb cells 14 during compression without damaging the honeycomb cells 14 or buckling the sidewalls 24 thereof.
However,
In this configuration, the preformed foam layer 3 has an initial thickness F/2 equal to about the height H1 of the honeycomb cells 14. Two of these thinner foam layers 3 are disposed on opposite sides of the honeycomb 1 in symmetrical mirror fashion. However, the adhesive layer 2 is preferably applied directly adjoining one side only, such as the top side, of the honeycomb 1 as shown schematically in
Both of the foam layers 3 are then simultaneously compressed into the honeycomb cells 14 from opposite sides of the core honeycomb 1 to fill corresponding top and bottom halves of the cells 14. The single adhesive layer 2 is simultaneously compressed by the top foam layer 3 into the cells 14 where the adhesive coats the cell sidewalls 24 and additionally bonds together the two foam fronts as they are compressed to meet near the middle of each cell.
In this alternate configuration, both the top and bottom surfaces of the core honeycomb 1 have foam disposed flush or even therewith, with the top and bottom foam plugs being adhesively bonded into each cell 14. Yet again, small voids 32 devoid of foam may be randomly found at the middle perimeter of each cell where the opposite foam plugs adjoin each other.
The so configured core honeycomb laminate 12 accordingly includes specially fabricated and configured foam 3, in plug form, adhesively bonded therein to effect a noise attenuating muffler in the center or middle of the structural panel 10.
Cooperating with this foam-filled core honeycomb laminate 12 are the two outer laminates 16, 18 each specially configured to include an imperforate acoustic layer or septum 4 directly adjoining the preformed core honeycomb laminate 12 disposed inboard of the outer skins 20,22 as shown in
The acoustic septums 4 bound or sandwich the foam-filled core honeycomb laminate 12 therebetween, and are rigid and imperforate to provide an additional form of sound suppression in the form of a reactive muffler that cooperates with the core honeycomb laminate 12 to collectively attenuate noise transmission from and through both sides of the core assembly.
This so-configured collective core assembly is rigid and also provides substantial strength for the finished structural panel 10, along with acoustic abatement.
Each of the two outer laminates 16, 18 preferably includes one imperforate acoustic septum 4 directly adjoining a corresponding opposite side of the preformed honeycomb laminate 12, followed by an outer or outboard honeycomb 5 directly adjoining the acoustic septum 4.
A plurality of directional structural fiber layers 6,7,8 adjoin the outer honeycomb 5 to define the outer skins 20,22 which integrally bound the so laminated acoustic panel 10.
Stacked atop opposite sides of the preformed honeycomb laminate 12 in turn are a prepreg epoxy-fiber septum 4, an outer honeycomb 5, and a plurality of prepreg epoxy directional structural fiber layers 6,7,8 to form a collective stack 12,16,18. Prepregs are conventional features in which material is pre-impregnated with suitable thermally curable resins, like common epoxy, which bonds together the fibers in a rigid resin matrix after heat curing.
This collective stack of individual components is then suitably compressed together under heat and pressure in a second press operation to thermally cure and form the unitary structural panel 10 having the preformed honeycomb laminate 12 bonded in the middle between the outer laminates 16, 18 each including a corresponding one of the outer honeycombs 5 bonded between the outer skins 20,22.
The structural fiber prepreg layers 6,7,8 include a first unidirectional fiber layer 6 directly adjoining the outer honeycomb 5 followed in turn by a second unidirectional fiber layer 7 disposed transversely to the first unidirectional layer 6 and terminating in a woven fiber layer 8 exposed outboard.
As shown in
The core honeycomb 1 includes hexagonal cells with height H1 and width W1. The top outer honeycomb 5 has height H2 and cell width W2. And, the bottom outer honeycomb 5 has height H3 and cell width W3.
The two outer honeycombs 5 are preferably identical in configuration with equal cell height and width.
But, in the preferred configuration, the core honeycomb 1 is made of metal, such as lightweight aluminum, and the outer honeycombs 5 are non-metal, such as Aramid fibers, and the honeycomb cells 14 of the former are larger than the cells of the latter, with the core honeycomb 1 being taller in height H1 than the heights H2 and H3 of the outer honeycombs 5, with correspondingly wider cells 14 having W1 being greater than W2 and W3.
The corresponding first directional layer 6 includes structural fibers, like strong carbon fibers, in tape form extending transversely along the Y-axis. The second directional layer 7 includes structural fibers, like strong carbon fibers, in tape form extending longitudinally along the X-axis. And, the outboard fiber layer 8 includes woven fibers, like fiberglass cloth, for both longitudinal and transverse strength.
Collectively, the three fiber layers 6,7,8 define respective ones of the outer and inner skins 20,22, and along with the core honeycomb 1 and two outboard honeycombs 5 effect substantial rigidity and strength to the final structural panel 10.
And, equally significant is the acoustic abatement performance of the finished panel 10 due to this special assembly of acoustic and structural features which cooperate for both enhanced panel strength and acoustic attenuation performance.
Acoustic abatement panels are well known and typically include cavities for sound suppression. In this regard, conventional acoustic abatement panels typically include a multitude of perforations in the outer skins thereof, as well as internally.
In stark contrast with conventional perforated panels, the acoustic panel 10 disclosed herein preferably has imperforate outer skins 20,22, and correspondingly imperforate structural fiber prepreg layers 6,7,8 bounding the two outer honeycombs 5.
It is possible that the outer skins 20,22 could be perforated in alternate embodiments, but further sound attenuation therefrom must be confirmed by further development and testing.
As disclosed above, the outer laminates 16, 18 preferably have imperforate acoustic septums 4 directly adjoining the preformed honeycomb laminate 12 disposed inboard of the outer skins 20,22. The outer honeycombs 5 directly adjoin the acoustic septums 4, and the directional structural fiber layers 6,7,8 define imperforate outer skins 20,22.
The acoustic septums 4 cooperate with the core honeycomb laminate 12 for collectively attenuating sound, and that preformed laminate 12 includes foam 3 filling each of the honeycomb cells 14 substantially completely. In contrast, the cells 14 of the outer honeycombs 5 are preferably empty and devoid of any foam.
The special method of fabrication disclosed above results in a correspondingly special finished structural panel 10 made by such method.
The two imperforate acoustic septums 4 are thusly directly bonded to the opposite sides of the center honeycomb laminate 12, and the two outer honeycombs 5 are in turn directly bonded to the septums 4. The directional structural fiber layers 6,7,8 are integrally bonded to the outer honeycombs 5 to collectively define the top and bottom outer laminates 16, 18 having the outer skins 20,22 integral therewith.
Accordingly, the acoustic structural panel 10 so fabricated undergoes two separate heating and pressing cycles, and the foam 3 plugging each of the core honeycomb cells 14 has a special configuration bonded to the inner surfaces of the cells by the separate and distinct adhesive 2 specifically provided for this purpose resulting in a unique collective configuration tested in development to have significant sound attenuation performance.
For example, since the perimeter of the rectangular panel 10 necessarily includes only portions of complete honeycomb cells, as shown in
The preformed core honeycomb laminate 12 disclosed above cooperates in the finished panel 10 to collectively provide therewith both substantial rigidity and strength, along with demonstrated sound attenuation or abatement in a configuration built and tested.
Various modifications of the significant features disclosed above may be pursued through development testing to obtain a final panel having the preformed acoustic foam specially pressed therein without damaging or buckling the lightweight core honeycomb 1 itself.
Presented in the Table below are examples of exemplary materials which may be used in fabricating an effective acoustic structural panel 10 for aircraft configurations:
In the Table presented above, the various layers are common products commercially available from various sources in the U.S.A. and abroad, in a multitude of material configurations having correspondingly different thermally curing cycles. And, all layers are provided in suitable form and size to cover the entire surface area across the desired length L and width W of the final panel 10.
In the preferred configuration, the core honeycomb 1 is entirely aluminum metal with sidewall thickness t of about 0.102 mm for maintaining light weight, while presenting sharp cutting edges for the acoustic foam 3.
The acoustic foam 3 must be sufficiently soft for being cut by the honeycomb cells 14 during fabrication without damaging or buckling the cell sidewalls 24.
In one configuration built and tested, the acoustic foam 3 comprises a polyethersulphone-based foamed core material made from a thermoplastic resin from the BASF Corporation, Florham Park, N.J., U.S.A.; and commercially available under the trademark Divinycell® F-50 from the Diab Group, Laholm, Sweden.
This F-50 foam material was successfully cut by the aluminum honeycomb cells during the first compression operation without any damage or buckling to the cells. However, another commercially available H-series variation of this foam material was also tested but was too strong and caused unsatisfactory buckling damage to the thin aluminum cell walls.
The outer non-metallic honeycombs 5 are preferably made of conventional Aramid fiber, and commercially available from various sources.
The remaining fiber, glass, and adhesive materials are also commercially available in various forms from various sources. Both the fiberglass woven layers 4,8 and the unidirectional carbon fiber tape layers 6,7 are preimpregnated with thermally curable epoxy resins which are thermally cured under the heating and pressing cycles to bind together all layers in a unitary finished structural panel having substantial strength and rigidity.
In the Example presented in the above Table, the two outer honeycombs 5 may be made from Kevlar® N636 para-aramid fiber commercially available from Plascore Incorporated, Zeeland, Mich., U.S.A.
These two nonmetallic honeycombs 5 have a density of 72 kg/m3 for collectively achieving in the finished panel 10 a suitable rigidity and strength for an aircraft cabin floor application.
Two other examples considered were identical to the Table Example except that the two Aramid honeycombs 5 had higher densities of 96 and 123 kg/m3 for further increasing panel rigidity and strength.
The core layers 1,2,3 and two bounding septum layers 4 have been specifically annotated in the Table for their special contribution to achieving the acoustic solution or noise uppression in the finished panel 10.
The improved panel design disclosed above integrally includes acoustic reduction properties based on the combination of multiple materials and distinct layers in the middle core subassembly. Core materials include honeycomb, fiberglass preimpregnated plies, film adhesive and foam. The manufacturing process to achieve the acoustic performance improvements divides the core assembly into preferably three layers which collectively act as noise isolators.
Driving the acoustic abatement improvement to the interior of the panel will reduce the need for secondary materials, thusly saving weight, and can reduce overall noise levels and increase passenger comfort.
The outer two layers bounding the core subassembly may be made from Aramid honeycomb core with a fiberglass prepreg septum bonded to the inner surface of the layer. The center layer of the core subassembly is preferably made from a combination acoustic foam being pressed into the cells of an aluminum honeycomb with an adhesive. A thicker layer of foam core as compared with the aluminum core is used to expand within cell walls and minimize edge gaps within the foam-to-cell wall contact area. This core assembly contains fiberglass ply septums acting as reactive muffler and the foam core acting as a dissipative muffler. The combination of both techniques is utilized to achieve acoustic attenuation or abatement.
The overall panel thickness may be unaffected when compared with traditional panel construction, and total aircraft weight impact is likely lighter than using secondary bonding of external sound abatement materials. The panel will maintain the strength properties of conventional sandwich panels.
The laminated composite sandwich panel 10 accordingly includes an internal acoustic abatement core assembly integrated with outer and inner panel skins into a standard panel construction for corresponding use in any structural panel applications, including, in particular, aircraft construction. The panel skins and the core layers can be sized to adjust for panel thickness, panel strength, or weight optimization. The acoustic core subassembly can be used on contoured panels as well as flat panels.
Layers 6,7,8 collectively define the first and second or outer and inner laminated skins, which can be separately configured as required for various structural applications.
Layers 4,5 define corresponding non-metallic honeycomb layers adhesively bonded integrally into the composite panel, with layers 5 defining sound attenuating septums.
Layers 1,2,3 are preformed to define the center core subassembly for internally introducing acoustic abatement or sound attenuation within the composite panel itself for substantially reducing sound transmission therethrough; and in combination with the bounding layers effectively dissipate noise or sound energy.
The combination of multiple septums 4 in exemplary embodiments for capturing sound internally within the sandwich panel itself, and using a dissipative material 3 is believed to create a sound absorption level beyond the sum of individual sound abatement techniques independently.
Internal sound dampening allows for noise abatement to be included in common aircraft components which otherwise have limited noise absorption opportunities or capabilities.
Layer 1 is the metallic, or aluminum, honeycomb sheet into which is pressed the acoustic foam material 3 atop the intervening adhesive film layer 2, which bonds the foam into each honeycomb cell under suitable processing heat to form an integrated foam-filled acoustic core subassembly 1-2-3.
Panel thickness, honeycomb configurations, and skin materials are customizable to meet strength, rigidity, and load requirements.
Specific sound frequency abatement may be customized by modifying configuration and material composition of the three honeycombs 1,5,5; acoustic foam 3, and adhesive layer 2; along with modifying configuration, plies, size, material, and orientation of fibers in the exemplary structural layers 4,6,7,8.
Furthermore, the acoustic panel 10 could be even further modified to include additional conventional noise abatement features provided that these additional features do not degrade acoustic abatement performance of the resulting panel.
Further testing would be required to develop how best to implement sound abatement in various configurations for different structural applications in aircraft, or any other application in which noise abatement is desired.
A typical aircraft includes various structural panels which may be modified herein for effecting significant sound attenuation, such as, for example, lavatory walls, stowage bins, floorboards, and additionally:
Floorboards to reduce aircraft mechanical systems noises to the cabin;
Cabin liner panels to minimize external to aircraft sounds;
Equipment racks and cockpit instrument panel to contain electronic noises; and
Cabinets, galleys, and lavatory walls to provide interior sound dampening of plumbing systems.
Exemplary benefits from the improved acoustic structural panel 10 include:
Combining two types of sound attenuation within a compact space and maintaining mechanical strength properties;
Potentially lighter panel compared with typical construction that requires external sound abatement materials;
Does not require skin perforation to attain sound absorption; prevents moisture or other contaminants from the panel;
Capable of flush mounting alongside other non-acoustic treated panels without need to accommodate secondary materials;
Panel design does not preclude the use of existing techniques for sound abatement;
This design does not add any complexity to the end use of the panel installation into cabinets, floorboards, or other products; and
The same processes and techniques, or various conventional manufacturing processes, can still be utilized to implement the improved acoustic abatement panel design.
Acoustic properties may be tunable for desired sound frequencies by material selections and sizing. Examples are cell sizes, material densities, and material types. Further testing will determine effectiveness of acoustic abatement, but the basic layer design need not change.
Accordingly, the acoustic abatement laminated panel 10 disclosed above can have various configurations, with various layers, and various materials, and various dimensions and thicknesses for providing internal sound abatement by the special combination of layers and materials thereof.
Different features may be varied for varying acoustic abatement, while also providing desired structural strength of the panel for its intended application.
The center acoustic core may be configured and varied for tailoring either or both of the reactive muffler or the dissipative muffler performance thereof for maximizing noise abatement performance, with or without additional conventional noise abatement features.
The outer and inner skins of the panel are preferably imperforate; but could be otherwise configured as desired provided they do not adversely affect strength of the panel, or the internal noise abatement performance thereof.
While there have been described herein what are considered to be preferred and exemplary embodiments of the present invention, other modifications of the invention shall be apparent to those skilled in the art from the teachings herein, and it is, therefore, desired to be secured in the appended claims all such modifications as fall within the true spirit and scope of the invention.
| Number | Date | Country | |
|---|---|---|---|
| 62555320 | Sep 2017 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16108494 | Aug 2018 | US |
| Child | 17494994 | US |
