CN107264815A - 隔音板、其制造方法及包括这种隔音板的飞行器发动机舱和飞行器 - Google Patents

隔音板、其制造方法及包括这种隔音板的飞行器发动机舱和飞行器 Download PDF

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CN107264815A
CN107264815A CN201710211107.4A CN201710211107A CN107264815A CN 107264815 A CN107264815 A CN 107264815A CN 201710211107 A CN201710211107 A CN 201710211107A CN 107264815 A CN107264815 A CN 107264815A
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panel
braided material
manufacture method
microporous layers
aircraft
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F·拉维斯
H·梅纳
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Airbus Operations SAS
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Abstract

隔音板、其制造方法及包括这种隔音板的飞行器发动机舱和飞行器。用于飞行器发动机舱的隔音板具有构造成抑制噪声的微孔层、固定于微孔层的一表面(5.2)的背板、以及固定于微孔层的另一相对表面的面板，面板具有预浸渍编织材料层，其包含彼此间隔开的纬线(7)和彼此间隔开的经线(8)，以使面板在经纱线之间具有孔(9)。本发明还涉及这种隔音板的制造方法及包括这种隔音板的飞行器发动机机舱和飞行器。根据本发明的这种隔音板制造快速、容易且成本低，同时在机械应力方面保持很大强度。

Description

隔音板、其制造方法及包括这种隔音板的飞行器发动机舱和 飞行器
技术领域
本发明涉及用于飞行器发动机舱的隔音板。
本发明还涉及用于飞行器发动机舱的这种隔音板的制造方法。
背景技术
飞行器，尤其是喷气式飞机，具有为重大的噪声发射源的涡轮喷气发动机。
为了减弱来自涡轮喷气发动机的噪声发射，这些涡轮喷气发动机的发动机舱配有隔音板，隔音板在进气口区域中镶于发动机舱内壁。
一般说来，这些隔音板具有夹层式结构。隔音板通常在模具中成形，以赋予隔音板以适于要安装这些隔音板的发动机舱的形状。这些隔音板具有一个或多个能抑制噪声的蜂窝式微孔结构层。这种微孔结构层具有外表面和内表面，所述外表面被覆以称为面板的多孔层，所述内表面被覆以称为背板的防渗层。
目前，用于隔音板的面板制造使用时间长的复杂工艺。例如，面板可利用焊接在一起的面板条带进行制造。装配后，这些面板条带需要完全人工检查以评估其质量。于是这些面板条带被焊接在一起，以覆盖成形隔音板的模具。例如，面板需要覆盖用于A380型飞行器发动机舱的模具的约12平方米的面积。因此，面板制造方法实施起来时间长、复杂且成本高昂。
存在这样的替换方式，其中，面板用穿孔层进行制造。穿孔可在隔音板的各层装配之前或之后进行。但是，将这些层穿孔的步骤会严重浪费制造这些层的材料。穿孔的步骤还可能削弱制造这些层的材料的结构。
发明内容
本发明的一目的在于通过提出一种制造快速、制造成本低且提供更好机械强度的隔音板来弥补这些缺陷。
为此，本发明涉及一种用于飞行器发动机舱的隔音板，其包括：
－微孔层，微孔层由第一表面和相对的第二表面限定，
－面板，面板固定于微孔层的第一表面，
－背板，背板固定于微孔层的第二表面，
面板具有预浸渍编织材料层，预浸渍编织材料层包含彼此间隔开的纬线和彼此间隔开的经线，以使面板在经纬线之间具有孔。
根据另一具体特征，纬线的相互间隔为0.3毫米至1.5毫米之间。
此外，经线的相互间隔为0.3毫米至1.5毫米之间。
本发明还涉及制造用于飞行器发动机舱的隔音板的制造方法，包括：
－将面板施加于模具的表面的步骤，
－将构造成抑制噪声的微孔层的第一表面固定于面板的固定步骤，
－将背板固定于微孔层的第二表面的固定步骤，第二表面是与第一表面相对的表面，
将面板施加于模具的表面的步骤在于：施加预浸渍编织材料层，预浸渍编织材料层包含彼此间隔开的纬线和彼此间隔开的经线，以便在经纬线之间形成孔。
另外，所述方法还包括制造面板的步骤，制造面板的步骤包括：
－编织步骤，编织步骤在于编织一层以使编织物的纬线彼此间隔开并且编织物的经线彼此间隔开，以便形成编织材料层，
－预浸渍步骤，预浸渍步骤在于预浸渍编织材料，以便形成预浸渍编织材料层。
根据一替换方式，预浸渍步骤包括：
－将编织材料浸渍到包含溶解于溶剂的树脂的浴中的步骤，以及
－进行干燥以使溶剂从预浸渍编织材料蒸发掉的步骤。
根据另一替换方式，预浸渍步骤包括：
－使用热熔方法将树脂施加于基质的步骤，以及
－用编织材料压制基质并且加热基质以使树脂浸渍编织材料的步骤。
可选地，将面板施加于模具的表面的步骤后跟随面板聚合步骤。
此外，将微孔层的第一表面固定于面板的固定步骤和将背板固定于微孔层的第二表面的固定步骤中的每个固定步骤均包括施加聚合粘合剂的步骤。
另外，将背板固定于微孔层的第二表面的固定步骤后跟随使面板与聚合粘合剂聚合的步骤。
本发明还涉及包括上述隔音板的飞行器发动机舱。
本发明还涉及包括这种发动机舱的飞行器。
附图说明
通过阅读参照附图所进行的说明，本发明及其特征和优点将更清楚地体现出来，附图中：
－图1表示其发动机舱具有隔音板的飞行器的俯视图；
－图2表示具有隔音板的飞行器发动机舱的透视图；
－图3表示根据一实施方式的隔音板的透视图；
－图4表示从用于形成隔音板的模具脱开的隔音板的透视图；
－图5表示隔音板的剖面图；
－图6表示根据一实施方式的隔音板的面板的俯视图；
－图7表示根据一实施方式的面板的近视图。
－图8表示根据本发明的用于飞行器发动机舱的隔音板的制造方法的步骤的流程图。
具体实施方式
本说明书描述的余下部分将参照上述附图进行。
本发明涉及用于飞行器1发动机舱2、尤其是运输机的发动机舱(图1)的隔音板3。
隔音板3可布置在飞行器1发动机舱2的内壁上(图2)。
如图3所示，所述隔音板3具有构造成抑制噪声的微孔层5。
微孔层5的结构具有一个或多个微孔结构子层。
例如，微孔层5的结构呈蜂窝式。
微孔层5由第一表面5.1和相对的第二表面5.2限定。
所述隔音板3还具有面板4和背板6，所述面板4固定于微孔层5的第一表面5.1，所述背板6固定于微孔层5的第二表面5.2。
背板6是不透气层。例如，背板6是炭层。
面板4具有预浸渍编织材料层，预浸渍编织材料层包含彼此间隔开的纬线7和彼此间隔开的经线8。面板4具有孔9，孔由成对纬线7之间和成对经线8之间的空间限定。
优选地，纱线7和8均匀间隔开。
优选地，纬线7之间的间隔D1与经线8之间的间隔D2相同。
非限制性地，纬线7之间的间隔D1为0.3毫米至1.5毫米之间。
仍非限制性地，经线8之间的间隔D2为0.3毫米至1.5毫米之间。
纬线7的纵向轴线7.1大致相互平行。
同样，经线8的纵向轴线8.1大致相互平行。
根据一替换方式，纬线7的纵向轴线7.1垂直于经线8的纵向轴线8.1。
根据另一替换方式，纬线7的纵向轴线7.1与经线8的纵向轴线8.1形成严格大于0°而小于90°的角。
优选地，面板4通过编织而成，以便控制纬线7相对于彼此的间隔D1和经线8相对于彼此的间隔D2。因此，在使用条件下，面板比现有技术的面板具有更大的机械强度。特别是，径向机械性能得到提高。
材料预浸渍的事实也可保持纬线7与经线8之间的间隔，在制造隔音板3期间尤其如此。
根据一替换实施方式，面板4的纤维通过三维编织而获得。
术语“纱线”的含义可延伸到任何能编织的细长体。术语“纱线”尤其可表示线或者条。
优选地，纱线7和8利用呈长丝形式的纤维制成。因此，纱线7和8可用纱线支数定义(即“tow count(纱支)”)。该纱线支数和长丝尺寸可确定间距D1与D2之间的距离d1和d2。
例如，制造纱线7和8的纤维是碳纤维。
因此，隔音板3具有显著特性，如相对于已知隔音板来说重量减轻并且空气动力型面改善。
本发明还涉及制造用于飞行器1发动机舱2的隔音板3的方法。
所述方法包括将面板4施加于模具10的表面10.1的步骤E1。模具10的表面10.1的形状适合于匹配用于配有隔音板3的发动机舱2的形状。
施加面板4的步骤E1在于施加如上所述的预浸渍编织材料层。面板4的施加可牵涉施加预浸渍编织材料束(或捆)形式或者预浸渍编织材料条带形式的预浸渍编织材料。例如，这些条带是卷绕条带，当施加面板4时而展开。束或者条带之间可能存在非连续的叠加区域，以确保结构的完整性。
所述方法还包括将微孔层5的第一表面5.1固定于面板4的固定步骤E2。
所述方法还包括将背板6固定于微孔层5的第二表面5.2的固定步骤E3。第二表面5.2是与微孔层5的第一表面5.1相对的表面。
此外，所述方法还包括制造面板4的预备步骤E4。该步骤E4在于，制造预浸渍编织材料层，预浸渍编织材料层包含彼此间隔开的纬线7和彼此间隔开的经线8，以便在经纬线7、8之间形成孔9。
在一实施方式中，制造面板4的步骤E4包括编织步骤E4.1，用以编织一层以使编织物的纬线7彼此间隔开并且编织物的经线8彼此间隔开，以便形成编织材料层。
此外，制造步骤E4包括预浸渍步骤E4.2，预浸渍步骤在于预浸渍编织材料，以便形成预浸渍编织材料层。
预浸渍步骤E4.2可使用不同的方法进行。
根据一实施方式，预浸渍步骤E4.2可使用以溶剂浸渍编织材料的方法(“溶剂浸泡工艺”或者“溶剂浸渍工艺”)进行。
根据这种方法，预浸渍步骤E4.2包括：
－将编织材料浸渍到包含溶解于溶剂的树脂的浴中的步骤E4.2.1，以及
－进行干燥以使溶剂从预浸渍编织材料蒸发掉的步骤E4.2.2。
根据另一实施方式，预浸渍步骤E4.2可使用热熔方法。
根据该方法，预浸渍步骤E4.2包括：
－使用热熔方法将树脂施加于基质的步骤E4.2.3，以及
－用编织材料压制基质并且加热基质以使树脂浸渍编织材料的步骤E4.2.4。
施加树脂的基质可以是纸。
特别是，该预浸渍步骤E4.2可在制造隔音板3的期间使纬线7和经线8保持彼此间隔开。
根据一替换实施方式，将面板4施加于模具10的表面10.1的步骤E1后跟随面板4聚合步骤E5。
根据一替换实施方式，每个固定步骤E2和E3包括施加聚合粘合剂的步骤E6.1、E6.2。
优选地，在该上一替换实施方式中，将背板6固定于微孔层5的步骤E3后跟随使聚合粘合剂聚合的步骤E7。如果聚合面板4的步骤E5没有在将面板4施加于模具10的表面10.1的步骤E1之后进行，那么，使聚合粘合剂聚合的步骤E7也包括聚合该面板。因此，这可允许将两个聚合步骤(面板的聚合，然后是粘合剂的聚合)结合成单一个步骤。
该方法可省去以下步骤：
－使用时间长、复杂且成本高昂的方法来制造面板4，
－人工检查以评估面板4的质量，
－聚合面板4的中间步骤。
因此，该方法可缩短制造隔音板3所花费的时间。

Claims (10)

1.一种用于飞行器(1)发动机舱(2)的隔音板，包括：
－微孔层(5)，微孔层(5)由第一表面(5.1)和相对的第二表面(5.2)限定，
－面板(4)，面板固定于微孔层(5)的第一表面(5.1)，
－背板(6)，背板固定于微孔层(5)的第二表面(5.2)，
隔音板(3)的特征在于，面板(4)具有预浸渍编织材料层，预浸渍编织材料层包含彼此间隔开的纬线(7)和彼此间隔开的经线(8)，以使面板(4)在经纬线之间具有孔(9)，纬线(7)的相互间隔(D1)为0.3毫米至1.5毫米之间，经线(8)的相互间隔(D2)为0.3毫米至1.5毫米之间。
2.一种用于飞行器(1)发动机舱(2)的隔音板(3)的制造方法，包括：
－将面板(4)施加于模具(10)的表面(10.1)的步骤(E1)，
－将构造成抑制噪声的微孔层(5)的第一表面(5.1)固定于面板(4)的固定步骤(E2)，
－将背板(6)固定于微孔层(5)的第二表面(5.2)的固定步骤(E3)，第二表面是与第一表面(5.1)相对的表面，
所述制造方法的特征在于，将面板(4)施加于模具(10)的表面(10.1)的步骤(E1)在于：施加预浸渍编织材料层，预浸渍编织材料层包含彼此间隔开的纬线(7)和彼此间隔开的经线(8)，以便在经纬线之间形成孔(9)，纬线(7)的相互间隔(D1)为0.3毫米至1.5毫米之间，经线(8)的相互间隔(D2)为0.3毫米至1.5毫米之间。
3.根据权利要求2所述的制造方法，其特征在于，所述制造方法还包括制造面板(4)的步骤(E4)，制造面板的步骤包括：
－编织步骤(E4.1)，编织步骤在于编织一层以使编织物的纬线(7)彼此间隔开并且编织物的经线(8)彼此间隔开，以便形成编织材料层，
－预浸渍步骤(E4.2)，预浸渍步骤在于预浸渍编织材料，以便形成预浸渍编织材料层。
4.根据权利要求3所述的制造方法，其特征在于，预浸渍步骤(E4.2)包括：
－将编织材料浸渍到包含溶解于溶剂的树脂的浴中的步骤(E4.2.1)，以及
－进行干燥以使溶剂从预浸渍编织材料蒸发掉的步骤(E4.2.2)。
5.根据权利要求3所述的制造方法，其特征在于，预浸渍步骤(E4.2)包括：
－使用热熔方法将树脂施加于基质的步骤(E4.2.3)，以及
－用编织材料压制基质并且加热基质以使树脂浸渍编织材料的步骤(E4.2.4)。
6.根据权利要求2至5中任一项所述的制造方法，其特征在于，将面板施加于模具的表面(10.1)的步骤(E1)后跟随面板聚合步骤(E5)。
7.根据权利要求2至5中任一项所述的制造方法，其特征在于，将微孔层的第一表面固定于面板的固定步骤(E2)和将背板固定于微孔层的第二表面的固定步骤(E3)中的每个固定步骤均包括施加聚合粘合剂的步骤(E6.1，E6.2)。
8.根据权利要求7所述的制造方法，其特征在于，将背板(6)固定于微孔层(5)的第二表面的固定步骤(E3)后跟随使面板(4)与聚合粘合剂聚合的步骤(E7)。
9.一种飞行器发动机舱，其中，飞行器发动机舱包括根据权利要求1所述的隔音板(3)。
10.一种飞行器，其中，飞行器包括根据权利要求9所述的飞行器发动机舱(2)。
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