CN111559490A - 制造吸声结构的方法、吸声结构和飞行器 - Google Patents

制造吸声结构的方法、吸声结构和飞行器 Download PDF

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CN111559490A
CN111559490A CN202010081435.9A CN202010081435A CN111559490A CN 111559490 A CN111559490 A CN 111559490A CN 202010081435 A CN202010081435 A CN 202010081435A CN 111559490 A CN111559490 A CN 111559490A
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sound
resin
skin
honeycomb
honeycomb structure
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T·里科贝内
F·多贝若尼
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Airbus Operations SAS
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Abstract

本发明涉及一种用于制造吸声结构的方法、吸声结构和飞行器。所述吸声结构包括声阻结构、蜂窝结构、反射层、以及还有多个声学元件，所述多个声学元件被定位在所述蜂窝结构中、抵靠所述声阻结构，所述方法包括：通过将树脂沉积在模具上来形成构成所述声学元件的包壳的蒙皮的步骤，所述模具具有基部，在所述基部上定位有被成形为与由所述声学元件的包壳界定的腔体相类似的突出形式，将支撑所述树脂的所述模具与所述蜂窝结构放置在一起的步骤，所述树脂被插入在所述模具与所述蜂窝结构之间，使所述树脂聚合以同时获得所述蒙皮的硬化以及还有所述蒙皮与所述蜂窝结构之间的接合的步骤，以及装配所述声阻结构和所述反射层的步骤。

Description

制造吸声结构的方法、吸声结构和飞行器
技术领域
本申请涉及一种用于生产包括形成多个包壳的蒙皮的吸声结构的方法，涉及一种根据所述方法获得的吸声结构，并且还涉及一种包括所述吸声结构的飞行器。
背景技术
根据现有技术的实施例，推进组件包括短舱，并且还包括定位在短舱内部的旁通式涡轮发动机。短舱和涡轮发动机的某些表面包括用于使噪声污染衰减的吸声结构。根据一个实施例，吸声结构包括多孔层、蜂窝状蜂窝层、以及反射层。
“UHBR”(超高旁通比)涡轮发动机具有以比目前市场上的某些涡轮发动机低的频率转动的风扇，并且因此吸声结构必须构造为以便使低频声波衰减。为了使这种声波衰减，蜂窝状蜂窝层必须具有显著的高度，这在质量、整体尺寸、以及制造方面是有害的。
2013年5月27日至29日在德国柏林举办的第19届AIAA/CEAS航空声学会议中，美国航空航天学会(American Institute of Aeronautics and Astronautics，AIAA)的题为“宽频带特殊声学吸收器概念的航空声学衬里应用[aero-acoustic liner applicationsof the broadband special acoustic absorber concept]，2013-2176”的文件中描述了使得可以吸收低频声波的吸声结构。根据可以在图1和图2中看到的实施例，吸声结构10包括与声波在其中传播的介质接触的多孔层12、蜂窝结构14、反射层16、以及还有多个声学元件18。这些声学元件中的每一个声学元件包括由多孔层12封闭的囊体20，以便界定腔体22，在该腔体中定位有远离囊体20的空心锥体24，该空心锥体具有在多孔层12处向外开口的孔26。每个锥体24包括至少一个声学孔口28，该至少一个声学孔口允许将锥体24的内部同锥体24与囊体20之间的空间之间进行连通，该至少一个声学孔口根据所期望的声学特性来确定位置和尺寸。
基于与亥姆霍兹谐振器和四分之一波长谐振器相同的原理，如此形成的吸声结构10使得可以有效地使由UHBR型涡轮发动机发出的低频声音衰减。
根据另一实施例，每个声学元件包括由多孔层封闭的囊体，该囊体定位在蜂窝结构14中。
根据一种操作方法，声学元件18由具有短纤维或无纤维填料的树脂通过模制或注射彼此独立地生产，并且被定位在蜂窝结构14中加工的压痕30中。声学元件18通过粘接或嵌入而连接至蜂窝结构14。
这种操作方法并不完全令人满意，因为所有声学元件18必须单独处理并定位在蜂窝结构14的压痕30中。此外，通过粘接或通过嵌入来链接将声学元件18和蜂窝结构14趋向于使如此获得的吸声结构10变硬，这可能难以与飞行器短舱的圆柱形导管的形式相匹配。最后，这个实施例在质量方面是有害的。
发明内容
本发明旨在弥补现有技术的全部或一些缺点。
为此目的，本发明涉及一种用于制造吸声结构的方法，所述吸声结构包括声阻结构、蜂窝结构、反射层、以及还有多个声学元件，每个声学元件包括包壳，所述包壳定位在所述蜂窝结构中、并且具有由抵靠所述声阻结构放置的边缘界定的开口，使得所述包壳和所述声阻结构界定腔体。
根据本发明，所述方法包括：通过将树脂沉积在模具上来形成构成所述声学元件的包壳的蒙皮的步骤，所述模具具有基部，在所述基部上定位有成形为与所述声学元件的腔体相类似的突出形式，将支撑所述树脂的所述模具与蜂窝结构放置在一起的步骤，所述树脂被插入在所述模具与所述蜂窝结构之间，使所述树脂聚合以同时获得所述蒙皮的硬化以及还有所述蒙皮与所述蜂窝结构之间的接合的步骤，以及装配所述声阻结构和所述反射层的步骤。
与通过注射获得的现有技术声学元件的包壳的厚度相比，本发明的方法使得可以同时获得具有相对较薄的厚度的多个包壳，这有助于减小声学元件的质量。
根据另一特征，所述模具由可变形或柔性材料生产。
根据第一变体，所述树脂被配置成在所述聚合步骤之后在所述蒙皮上赋予硬度，并且其特征在于，所述模具具有成形为与待生产的所述吸声结构相类似的基部。
根据第二变体，所述树脂被配置成在所述聚合步骤之后获得柔性蒙皮。
根据一个实施例，所述树脂是聚氨酯/环氧混合树脂。
根据一个实施例，所述树脂呈在模具上变形或热成型的膜的形式。
根据另一实施例，所述树脂处于液态或糊状状态，并通过喷涂、通过涂覆或通过浸渍沉积在模具上。
根据另一特征，在所述聚合步骤时，所述树脂被定位在所述模具与互补模具之间。
根据另一特征，所述蒙皮由在通过浮动链接件连接在一起的独立模具上生产的多个部分构成。
本发明还涉及一种通过上述方法获得的吸声结构，所述吸声结构包括声阻结构、蜂窝结构、反射层、以及还有多个声学元件，每个声学元件包括包壳，所述包壳定位在所述蜂窝结构中、并且具有由抵靠所述声阻结构放置的边缘界定的开口，使得所述包壳和所述声阻结构界定腔体。根据本发明，所述吸声结构包括至少一个蒙皮，所述至少一个蒙皮具有通过共面材料带连接在一起的多个空心形式，每个空心形式成形为与包壳相类似，所述蒙皮被插入在所述蜂窝结构与所述声阻结构之间。
附图说明
本发明还涉及一种包括至少一个这种吸声结构的飞行器。
其他特征和优点将从本发明的以下描绘中显现，该描绘仅仅是通过举例方式参照附图给出的，在附图中：
[图1]是吸声结构的透视图，展示一个现有技术实施例，
[图2]是可以在图1中看到的吸声结构在组装过程中的透视图，
[图3]是飞行器的侧向视图，
[图4]是穿过飞行器的推进组件的导管的一部分的纵向截面，
[图5]是穿过吸声结构的一部分的截面，展示了本发明的一个实施例，
[图6]是穿过被成形为获得形成多个包壳的蒙皮的模具的横向截面，展示了本发明的一个实施例，
[图7]是模具的透视图，展示本发明的一个实施例，
[图8]是穿过形成被放置在图6中可以看见的模具上的多个包壳的蒙皮的横向截面，展示了本发明的一个实施例，
[图9]是穿过在与蜂窝结构放置在一起的步骤时被放置在可以在图8中看到的模具上的蒙皮的横向截面，展示了本发明的第一实施例，
[图10]是穿过形成在与蜂窝结构放置在一起的步骤时被放置在模具上的多个包壳的蒙皮的横向截面，展示了本发明的第二实施例，
[图11]是穿过配备有形成多个包壳的蒙皮的蜂窝结构的、的横向截面，展示了本发明的一个实施例，
[图12]是配备有形成多个包壳的蒙皮的蜂窝结构的俯视图，展示了本发明的一个实施例，并且
[图13]是穿过图12中可以看见的蜂窝结构的横向截面。
具体实施方式
图3示出了飞行器32，该飞行器包括机身34，布置在机身34两侧的两个机翼36、以及固定在机翼36下方的推进组件38。每个推进组件38包括短舱40和定位在短舱40内的涡轮发动机42。
根据图4中展示的一个实施例，每个推进组件38包括喷射导管44，该喷射导管由与短舱40成一体的外壁46并且由与涡轮发动机42成一体的内壁48界定。
根据一种构型，每个内壁46或外48包括至少一个吸声结构50，该至少一个吸声结构具有与声波在其中传播的介质接触的外表面SE。
尽管在应用于喷射导管44方面进行了描述，但是本发明不限于这种应用。因此，吸声结构50可以被定位在飞行器的具有与声波在其中传播的介质接触的外表面的任何壁处。
吸声结构50包括：声阻结构52，该声阻结构具有形成吸声结构50的外表面SE的外部面52.1、与外部面52.1相反的内部面52.2；蜂窝结构54；反射层56；以及还有多个声学元件58，该多个声学元件被定位在蜂窝结构54中、抵靠声阻结构52的内部面52.2。
根据一个实施例，蜂窝结构54是蜂窝状类型的，包括并置且具有给定截面的多个穿通小室59。根据可以在图5中看到的实施例，声阻结构52包括至少在与声学元件58对正的地方是多孔的至少一个面板。自然地，本发明不限于此实施例。因此，声阻结构52可以在其整个表面上是多孔的。
根据在图5中可以看到的实施例，每个声学元件58包括包壳60(也称为囊体)，该包壳具有开口62，该开口由抵靠声阻结构52的内部面52.2放置的边缘界定，使得包壳60和声阻结构52界定腔体64，声学孔口66穿过包壳60以将腔体64放置成与蜂窝结构54的小室59连通。
每个包壳60可以如图5所示是截头圆锥形的、如图12所示的呈截头棱锥体的形式、或者具有任何其他形式。
根据图11至图13中可以看到的另一实施例，每个声学元件58包括包壳60(也称为囊体)，该包壳具有开口62，该开口由抵靠声阻结构52的内部面52.2放置的边缘界定，使得包壳60和声阻结构52界定与蜂窝结构52的小室59连通或不连通的腔体64。
根据一种构型，蜂窝结构54的小室59和声学元件58的包壳60的尺寸被确定成使得每个包壳60被容纳在小室59中。
根据图5中可以看见的布置，声学元件58被布置成多行和多列。
自然地，本发明不限于用于声学元件58的这种布置和/或限于这些实施例。
根据本发明的一个特征，吸声结构50包括至少一个蒙皮68，该至少一个蒙皮具有通过共面材料带72连接在一起的多个空心形式70，每个空心形式70成形为与包壳60相类似，所述蒙皮68被插入在蜂窝结构54与声阻结构52之间。
根据情况，吸声结构50包括在其整个表面上延伸的单个蒙皮68或者插入蜂窝结构54与声阻结构52之间的多个蒙皮68。
根据在图9至图13中可以看到的第一实施例，空心形式70的尺寸和布置被确定为使得每个空心形式被容纳在蜂窝结构54的小室59中的一个小室中。
根据另一实施例，空心形式70具有比蜂窝结构54的小室59的截面大的截面。在这种情况下，蜂窝结构54包括通过任何合适的方式产生的压痕(例如通过机械加工)，使得每个压痕容纳空心形式70。
根据本发明的一个特征，具有空心形式70的蒙皮68通过具有基部76的模具74获得，该基部上定位有成形为与声学元件58的腔体64相类似的突出形式78。
根据一个实施例，模具74由可变形或柔性材料制成，以便于脱模，并使其能够适应蜂窝结构54的几何形状的不精确性。作为示例，模具74由硅树脂制成。
蒙皮68由树脂生产。根据一个实施例，树脂是环氧树脂。
根据另一实施例，树脂是聚氨酯/环氧混合树脂，以便获得适于变形的柔性蒙皮68。根据这个实施例，当蒙皮68紧固到蜂窝结构54时，该蜂窝结构保持其变形的能力。
如果所使用的树脂在聚合后在蒙皮68上赋予硬度，则当蒙皮68被紧固至所述蜂窝结构54时，该蒙皮将使蜂窝结构54在形式方面稳定。因此，模具74可以具有基部76，该基部是不平坦的、但是被成形为与待生产的吸声结构50完全相同。
根据第一实施例，树脂呈在模具上变形或热成型的膜的形式74。
根据第二实施例，树脂处于液态或糊状状态，并通过喷涂、通过涂覆或通过浸渍沉积在模具74上。在这种情况下，树脂包含辅助剂以限制其流动。作为示例，树脂由于填料而具有触变性。
用于生产配备有形成多个包壳60的蒙皮68的蜂窝结构的方法包括通过将树脂放置在模具74上来形成蒙皮68的步骤，将模具74与蜂窝结构54放置在一起的步骤，以及使树脂聚合以同时获得蒙皮68的硬化以及蒙皮68与蜂窝结构54之间的接合的步骤。
除了这些步骤之外，用于生产吸声结构的方法包括装配声阻结构52和反射层56的步骤。
用于蒙皮68的树脂可以在成形步骤结束时部分聚合。在所有情况下，树脂在放置到一起的步骤结束时并未完全聚合，以在聚合步骤时获得蒙皮68和蜂窝结构54之间的接合。
在放置到一起的步骤时，树脂被插入在模具74与蜂窝结构54之间。由树脂覆盖的模具74通过将模具74的突出形式78插入小室59中或蜂窝结构54的压痕中而被放置在蜂窝结构54上，或者蜂窝结构54被定位在模具74上，从而使得模具74的突出形式78与小室59或与蜂窝结构54的压痕相互作用。
根据在图10中可以看到的另一操作方法，在聚合步骤之前，蜂窝结构54被定位在互补模具80上，该互补模具具有穿透蜂窝结构54的小室59的突出形式。在这种情况下，在聚合步骤时，蒙皮68被插入在模具74与互补模具80之间。这种构型允许校准蒙皮68的厚度。
根据一种操作方法，吸声结构50的蒙皮68由在独立模具74上生产的多个并置部分构成。在这种情况下，各种模具74通过浮动连链接件连接在一起，以便自动地适应蜂窝结构54的不规则性。
与通过注射获得的现有技术声学元件的包壳的厚度相比，本发明的方法使得可以同时获得具有相对较薄的厚度的多个包壳60，这有助于减小声学元件58的质量。
当蒙皮68是柔性的时，可以根据所需的曲率使蜂窝结构54变形，并通过将声阻结构52和反射层56以粘合在一起而使其稳定在这个曲率上。

Claims (11)

1.一种用于制造吸声结构的方法，所述吸声结构包括声阻结构(52)、蜂窝结构(54)、反射层(56)、以及还有多个声学元件(58)，每个声学元件包括包壳(60)，所述包壳定位在所述蜂窝结构(54)中、并且具有由抵靠所述声阻结构(52)放置的边缘界定的开口(62)，使得所述包壳(60)和所述声阻结构(52)界定腔体(64)，其特征在于，所述方法包括：
-通过将树脂沉积在模具(74)上来形成构成所述声学元件(58)的包壳(60)的蒙皮(68)的步骤，所述模具具有基部(76)，在所述基部上定位有成形为与所述声学元件(58)的腔体(64)相类似的突出形式(78)，
-将支撑所述树脂的所述模具(74)与蜂窝结构(54)放置在一起的步骤，所述树脂被插入在所述模具(74)与所述蜂窝结构(54)之间，
-使所述树脂聚合以同时获得所述蒙皮(68)的硬化以及还有所述蒙皮(68)与所述蜂窝结构(54)之间的接合的步骤，以及
-装配所述声阻结构(52)和所述反射层(56)的步骤。
2.根据权利要求1所述的方法，其特征在于，所述模具(74)由可变形或柔性材料生产。
3.根据权利要求1或2所述的方法，其特征在于，所述树脂被配置成在所述聚合步骤之后在所述蒙皮(68)上赋予硬度，并且其特征在于，所述模具(74)具有成形为与待生产的所述吸声结构相类似的基部(76)。
4.根据权利要求1或2所述的方法，其特征在于，所述树脂被配置成在所述聚合步骤之后获得柔性蒙皮(68)。
5.根据前一权利要求所述的方法，其特征在于，所述树脂是聚氨酯/环氧混合树脂。
6.根据前述权利要求之一所述的方法，其特征在于，所述树脂呈在所述模具(74)上变形或热成型的膜的形式。
7.根据权利要求1至5之一所述的方法，其特征在于，所述树脂处于液态或糊状状态，并且通过喷涂、通过涂覆或通过浸渍沉积在所述模具(74)上。
8.根据前述权利要求之一所述的方法，其特征在于，在所述聚合步骤时，所述树脂被定位在所述模具(74)与互补模具(80)之间。
9.根据前述权利要求之一所述的方法，其特征在于，所述蒙皮(68)由在通过浮动链接件连接在一起的独立模具(74)上生产的多个部分构成。
10.一种通过根据前述权利要求之一所述的方法获得的吸声结构，所述吸声结构包括：声阻结构(52)、蜂窝结构(54)、反射层(56)、以及还有多个声学元件(58)，每个声学元件包括包壳(60)，所述包壳定位在所述蜂窝结构(54)中、并且具有由抵靠所述声阻结构(52)放置的边缘界定的开口(62)，使得所述包壳(60)和所述声阻结构(52)界定腔体(64)，其特征在于，所述吸声结构包括至少一个蒙皮(68)，所述至少一个蒙皮具有通过共面材料带(72)连接在一起的多个空心形式(70)，每个空心形式成形为与包壳(60)相类似，所述蒙皮(68)被插入在所述蜂窝结构(54)与所述声阻结构(52)之间。
11.一种飞行器，所述飞行器包括至少一个根据前一权利要求所述的、通过根据权利要求1至9之一所述的方法获得吸声结构。
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