The present disclosure relates generally to structural noise suppression systems and, more particularly, to acoustic panels used to suppress noise in aircraft gas turbine engine systems.
Acoustic panels may be used for noise suppression in aerospace applications and other fields. The panels typically comprise two skin surfaces that sandwich between them at least one layer of a core material or structure. The two skins and the core structure may be bonded together or cured or otherwise formed together, but mechanical fastening is also used in some applications. The core structure ties the skins together structurally and can form a very rigid, efficient and lightweight structure for noise suppression useful in aerospace applications. The panels may be given acoustic properties by perforating one skin (typically an air washed side of the panel) with specifically sized holes. This enables the cells of the core structure to act like individual Helmholtz resonators that attenuate a certain tone or tones, at specific frequencies or wavelengths, of noise generated by an engine. Further, additional layers of core structure, separated by additional skins, sheets or septa, may be used to attenuate multiple tonal frequencies. In many applications, the acoustic sandwich panel serves a structural role in addition to an acoustic role, but in some applications the structural function may be secondary to the acoustics. In aerospace applications, nacelles that house turbofan gas turbine engines may use acoustic panels to form the inner barrel of the inlet, the inner fixed structure of a thrust reverser, the translating sleeve of a translating sleeve type thrust reverser or portions of an exhaust system.
An acoustic panel is disclosed. In various embodiments, the acoustic panel includes a first layer; a cell having a first cell end connected to the first layer and a second cell end spaced a cell length from the first cell end, the cell having a first wall extending between the first cell end and the second cell end; and a septum having a central portion positioned within the cell and a first tab extending from the central portion, the first tab defining a first surface positioned against the first wall and a first distal end positioned adjacent the first layer.
In various embodiments, the cell includes a second wall extending between the first cell end and the second cell end and the septum includes a second tab extending from the central portion. In various embodiments, the second tab includes a second surface positioned against the second wall. In various embodiments, the second tab includes a second distal end positioned adjacent the first layer. In various embodiments, the first distal end of the first tab and the second distal end of the second tab are secured to the first layer by an adhesive. In various embodiments, the first tab is secured to the first wall by a first weld and the second tab is secured to the second wall by a second weld. In various embodiments, the septum comprises a mesh and, in various embodiments, the mesh comprises stainless steel.
In various embodiments, the first tab defines a first proximal end connected to the central portion and a first tab length extending from the first proximal end to the first distal end. In various embodiments, the first tab length is between about twenty-five percent and about seventy-five percent of the cell length. In various embodiments, the cell defines a cell cross-sectional shape in a form of a polygon. In various embodiments, the polygon is one of a triangle, a square and a hexagon.
In various embodiments, the cell includes a second wall extending between the first cell end and the second cell end and the septum includes a second tab extending from the central portion. In various embodiments, the second tab defines a second proximal end connected to the central portion, a second distal end positioned adjacent the first layer, and a second tab length extending from the second proximal end to the second distal end, the second tab length equal to the first tab length. In various embodiments, the first distal end of the first tab and the second distal end of the second tab are secured to the first layer by an adhesive. In various embodiments, the first tab is secured to the first wall by a first weld and the second tab is secured to the second wall by a second weld.
A septum for an acoustic panel is disclosed. In various embodiments, the septum includes a central portion configured for positioning within a cell; a first tab extending from the central portion, the first tab defining a first surface configured for positioning against a first wall of the cell and a first distal end configured for positioning adjacent a first layer of the acoustic panel; and a second tab extending from the central portion, the second tab defining a second surface configured for positioning against a second wall of the cell and a second distal end configured for positioning adjacent the first layer of the acoustic panel. In various embodiments, the cell defines a cell cross-sectional shape in a form of one of a triangle, a square and a hexagon.
A method of fabricating an acoustic panel is disclosed. In various embodiments, the method includes the steps of providing a core structure having a cell, the cell having a first cell end and a second cell end spaced from the first cell end; inserting a septum into the cell, the septum having a central portion configured for positioning within the cell, a first tab extending from the central portion, and a second tab extending from the central portion; positioning the first tab against a first wall of the cell and a first distal end of the first tab adjacent the first cell end of the cell; positioning the second tab against a second wall of the cell and a second distal end of the second tab adjacent the first cell end of the cell; and adhering one of a back-skin and a perforated layer to the first distal end of the first tab, the second distal end of the second tab, the first wall proximate the first cell end of the cell and the second wall proximate the first cell end of the cell. In various embodiments, the method further includes the step of welding the first tab to the first wall and the second tab to the second wall.
The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the following detailed description and claims in connection with the following drawings. While the drawings illustrate various embodiments employing the principles described herein, the drawings do not limit the scope of the claims.
The following detailed description of various embodiments herein makes reference to the accompanying drawings, which show various embodiments by way of illustration. While these various embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, it should be understood that other embodiments may be realized and that changes may be made without departing from the scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected, or the like may include permanent, removable, temporary, partial, full or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. It should also be understood that unless specifically stated otherwise, references to “a,” “an” or “the” may include one or more than one and that reference to an item in the singular may also include the item in the plural. Further, all ranges may include upper and lower values and all ranges and ratio limits disclosed herein may be combined.
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In various embodiments, the outer layer 306 may be formed from any suitable material, including, for example, metals, such as titanium or aluminum, plastics, such as phenolics, and composites, such as fiber reinforced composites. The inner layer 308 may be formed of similar materials. In various embodiments, the inner layer 308 and the outer layer 306 are formed of the same material, while in other embodiments, the inner layer 308 and the outer layer 306 are formed of different materials. In various embodiments, the outer layer 306 is impervious to airflow and the inner layer 308 is perforated. The size, number and spacing of perforations may depend on the acoustic requirements. For example, in various embodiments, the perforations are between about 0.030 inches (≈0.76 mm) and about 0.100 inches (≈2.54 mm) in diameter. In various embodiments, the perforations provide about 15% to about 35% open area and may be arranged in a uniform pattern across the inner layer 308.
The core structure 310 may be formed of any suitable material including, for example, metals, such as titanium, aluminum and alloys thereof, or ceramics and composite materials. In various embodiments, the core structure 310 is a honeycomb structure comprising tessellated polygons, such as, for example, squares or hexagons. In various embodiments, for example, including the embodiment illustrated in
Each septum 320 may be formed of any suitable material. Such materials are typically provided as relatively thin sheets that are perforated, porous or an open mesh fabric designed to provide noise attenuation. Each septum 320, for example, may be formed of a perforated or porous sheet of metal, ceramic or thermoplastic. In various embodiments, each septum 320 is formed of an open mesh fabric woven from monofilament fibers. The fibers may comprise glass, carbon, ceramic or polymers. By way of example, the fibers comprise monofilament polymer fibers made from one or more of polyamide, polyester, polyethylene chlorotrifluoroethylene (ECTFE), ethylene tetrafluoroethylene (ETFE), polytetrafluoroethyloene (PTFE), polyphenylene sulfide (PPS), polyfluoroethylene propylene (FEP), polyether ether ketone (PEEK), polyamide 9 (Nylon, 9 PA6) and polyamide 12 (Nylon 12, PA12).
As mentioned above, the septum 320 may be formed from a woven cloth or mesh. Suitable materials for the woven cloth or mesh include stainless steel, aluminum and titanium or mixtures thereof. The woven cloth or mesh may also be made of non-metallic materials, such as those described above. A stainless steel woven material is strong, light weight and has desirable sound attenuation characteristics. As also mentioned above, the septum 320 may be bonded to the core structure 310 using an adhesive. Exemplary adhesives include low solvent solution sprayable adhesives, adhesive films, epoxies, acrylics, phenolics, cyanoacrylates, bismaleimides, polyamine-imides and polyimides.
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In various embodiments, each cell of the plurality of cells 412 defines a first cell end 440 configured for connection to a first layer 442 (e.g., to the inner layer 408) and a second cell end 444 configured for connection to a second layer 446 (e.g., to the outer layer 406). The first cell end 440 and the second cell end 444 define a cell length 448. The septum 420 includes a central portion 450 that is positioned within the cell at a location along the cell length 448, the location generally falling within a range of from about twenty-five percent (25%) to about seventy-five percent (75%) of the cell length 448 from the first cell end 440. In various embodiments, the septum 420 includes a first tab 452 extending from the central portion 450, the first tab 452 defining a first surface 454 configured for positioning against a first wall 456 of the cell and a first distal end 458 configured for positioning adjacent the first layer 442.
In various embodiments, each cell of the plurality of cells 412 includes a second wall 460 extending along the cell length 448 between the first cell end 440 and the second cell end 444 and the septum 420 includes a second tab 462 extending from the central portion 450. The second tab 462 includes a second surface 464 configured for positioning against the second wall 460 and a second distal end 466 configured for positioning adjacent the first layer 442. In various embodiments, the first tab 452 is secured to the first wall 456 by a first weld 468 and the second tab 462 is secured to the second wall 460 by a second weld 470. In various embodiments, the first distal end 458 of the first tab 452 and the second distal end 466 of the second tab 462 are secured to the first wall 456 and to the second wall 460, respectively, by the adhesive 430. In various embodiments, the first distal end 458 of the first tab 452 and the second distal end 466 of the second tab 462 are secured to the first wall 456 and to the second wall 460, respectively, and to the first layer 442, by the adhesive 430. In various embodiments, the first wall 456 and the second wall 460 are secured to the second layer 446 proximate the second cell end 444 by the adhesive 430.
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In various embodiments, the first tab length 474 is equal to the second tab length 478, leading to the central portion 450 of the septum 420 being substantially perpendicular to the first wall 456 and to the second wall 460. In various embodiments, the first tab length 474 is not equal to the second tab length 478, leading to the central portion 450 of the septum 420 being substantially non-perpendicular to the first wall 456 and to the second wall 460. By selecting the tab lengths of the various tabs and positioning the respective distal ends of the tabs proximate the first end of the corresponding cell, the central portion of the septum may be accurately positioned within the cell at a desired location. Positioning the central portion 450 of the septum 420 at different depths along the cell length 448 facilitates acoustic tuning of the noise suppression system 400. In various embodiments, for example, positioning the central portion 450 proximate the inner layer 408 (e.g., the perforated layer 414) provides for linear acoustic noise suppression while positioning the central portion 450 farther away from the inner layer 408 tends to provide for more DDOF performance. Further, selecting identical geometries for all septa enables the central portions of all septa to be positioned at the same axial location within each cell among a plurality of cells throughout a core structure, facilitating uniformity throughout the resulting acoustic panel.
As described further below, in various embodiments, the first tab 452 may be deformed or bent from a sheet of material forming the septum 420 at the first proximal end 472, such that a substantially right angle is formed between the first tab 452 and the central portion 450. Similarly, the second tab 462 may be deformed or bent from the sheet of material forming the septum 420 at the second proximal end 476, such that a substantially right angle is formed between the second tab 462 and the central portion 450. The deformed septum may then be inserted into the cell and welded or adhered as described above. Note that while the foregoing describes formation of the septum 420 having the first tab 452 and the second tab 462, the disclosure contemplates any number of tabs being constructed, formed and attached to cell walls in the same manner to provide for septa having various cross sectional shapes, such as, for example, square (e.g., as illustrated in
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Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosure. The scope of the disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. Different cross-hatching is used throughout the figures to denote different parts but not necessarily to denote the same or different materials.
Systems, methods and apparatus are provided herein. In the detailed description herein, references to “one embodiment,” “an embodiment,” “various embodiments,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.
Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f) unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Finally, it should be understood that any of the above described concepts can be used alone or in combination with any or all of the other above described concepts. Although various embodiments have been disclosed and described, one of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. Accordingly, the description is not intended to be exhaustive or to limit the principles described or illustrated herein to any precise form. Many modifications and variations are possible in light of the above teaching.