阅读说明：本技术 用于环境控制系统的带有泡沫填充蜂窝芯的声音吸收管道
(Sound absorbing duct with foam filled honeycomb core for environmental control system
) 是由 D·D·玛本
B·A·范戴克
M·M·吉姆瑞克
D·R·C·卡纳尔 于 2019-08-20 设计创作，主要内容包括：本申请公开用于环境控制系统的带有泡沫填充蜂窝芯的声音吸收管道。一种管道包括具有管状形状的泡沫填充蜂窝芯结构。管道还包括不透气管道壁,该管道壁耦接到泡沫填充蜂窝芯结构的外表面。(The application discloses a sound absorbing duct with a foam filled honeycomb core for an environmental control system. A duct includes a foam-filled honeycomb core structure having a tubular shape. The duct also includes an air-impermeable duct wall coupled to an outer surface of the foam-filled honeycomb core structure.)
1. A conduit (102C) comprising:
a foam-filled honeycomb core structure (144) having a tubular shape; and
an air-impermeable duct wall (146) coupled to an exterior surface of the foam-filled honeycomb core structure.
2. The duct of claim 1, wherein the foam-filled honeycomb core structure has a structural honeycomb portion (172) comprising a metal, a composite material, or a combination thereof, and defining a plurality of cavities (174).
3. The duct of claim 2, wherein the foam-filled honeycomb core structure has foam (176) in the plurality of cavities, and wherein the foam of the foam-filled honeycomb core structure comprises open-cell foam (152).
4. The pipe of claim 3, wherein the open-cell foam comprises melamine foam.
5. The conduit of any one of claims 1-4, wherein the air-impermeable conduit wall comprises a non-rigid insulating layer (116, 162, 166).
6. The duct of claim 5, further comprising a tape (622) coupled to the non-rigid insulating layer, the tape configured to constrain and seal the non-rigid insulating layer, and wherein the tape comprises Metalized Polyetheretherketone (MPEEK).
7. The conduit of claim 1, wherein the air-impermeable conduit wall comprises a rigid tube (166) of composite material (126).
8. The duct of claim 7, wherein the composite material comprises a fabric material having a leno weave arrangement.
9. The duct of claim 1, wherein the foam-filled honeycomb core structure further comprises an inlet, an outlet opposite the inlet, and an inner surface opposite the outer surface, and wherein the foam-filled honeycomb core structure is configured to absorb sound, insulate the duct, and structurally support the duct.
10. The duct of claim 1, further comprising a composite rigid gas permeable tube (112, 132, 136) or a closed cell foam layer (135) coupled to an inner surface of the foam-filled honeycomb core structure.
11. A method (1600) of manufacturing a pipe, the method comprising:
creating (1602) a honeycomb core structure (172) having a tubular shape, the honeycomb core structure comprising a plurality of hexagonal cavities (174);
filling (1604) the plurality of hexagonal cavities of the honeycomb core structure with foam (176) to produce a foam-filled honeycomb core structure (144); and
coupling (1606) an air-impermeable duct wall (146) to an outer surface of the foam-filled honeycomb core structure.
12. The method of claim 11, wherein filling the plurality of hexagonal cavities of the honeycomb core structure with the foam comprises depositing (1612) the foam in the plurality of hexagonal cavities or creating (1614) the foam within the plurality of hexagonal cavities.
13. The method of any of claims 11-12, wherein the air-impermeable duct wall comprises a non-rigid insulating layer (116, 162, 164, 166), and further comprising coupling (1622, 1624) a rigid perforated tube (112, 132, 136) of composite material or a closed-cell foam (134) to an inner surface of the foam-filled honeycomb core structure.
14. The method of any of claims 11-13, wherein the air-impermeable duct wall comprises a rigid tube of composite material (126), and further comprising coupling (1622, 1624) a rigid perforated tube of composite material (112, 132, 136) or a closed-cell foam (134) to an inner surface of the foam-filled honeycomb core structure.
Technical Field
The present disclosure relates generally to ducts with sound absorbing foam filled honeycomb cores for environmental control systems.
Background
Vehicles, such as aircraft, include environmental control systems that provide treated air (e.g., conditioned air, filtered air, etc.) to passengers. Environmental control systems typically include ducts that deliver treated air to occupants of the vehicle. The treated air moving within the duct creates noise, which may reduce passenger comfort. Noise attenuating mufflers (e.g., zone mufflers) are commonly used to reduce (e.g., absorb) the noise generated by moving air. For example, mufflers surround the pipes of the environmental control system and use insulation and/or chambers to attenuate noise. However, noise attenuating mufflers add weight, volume and cost to the environmental control system. In high performance vehicles, such as aircraft, the increased weight and volume increases cost and reduces performance.
Disclosure of Invention
In one example, a pipe includes a rigid gas permeable tube of a composite material. The duct also includes an insulation layer coupled to an outer surface of the rigid gas permeable tube. The pipe further includes a non-rigid insulation layer in contact with the insulation layer. The non-rigid insulating layer forms an air-impermeable duct wall.
In another particular example, a pipe includes a rigid tube of composite material. The conduit further includes an insulation layer disposed within the rigid tube. The conduit also includes a biasing member disposed within the rigid tube. The biasing member is configured to restrain the insulation layer against an inner surface of the rigid tube.
In one particular example, a method of manufacturing a duct includes applying an insulating material to an outer surface of a rigid gas permeable tube of a composite material to form an insulating layer on the outer surface of the rigid gas permeable tube. The method further includes applying a non-rigid insulating material onto an outer surface of the insulating layer to form a non-rigid insulating layer in contact with the insulating layer, the non-rigid insulating layer forming an air-impermeable duct wall.
In another particular example, a method of manufacturing a pipe includes inserting an insulating material into a rigid tube of composite material to form an insulating layer within the rigid tube. The insulating layer is in contact with the inner surface of the rigid tube. The method also includes inserting a biasing member into the rigid tube of composite material to secure the insulating layer within the rigid tube.
In yet another particular example, a duct includes a foam-filled honeycomb core structure having a tubular shape. The duct also includes an air-impermeable duct wall coupled to an outer surface of the foam-filled honeycomb core structure.
In yet another particular example, a method of manufacturing a pipe includes creating a honeycomb core structure having a tubular shape. The honeycomb core structure includes a plurality of hexagonal cavities. The method also includes filling a plurality of hexagonal cavities of the honeycomb core structure with foam to produce a foam-filled honeycomb core structure. The method also includes coupling the air-impermeable duct wall to an outer surface of the foam-filled honeycomb core structure.
In one particular example, a method of installing a duct on a vehicle includes installing the duct in an environmental control system of the vehicle, wherein the duct includes a foam-filled honeycomb core structure having a tubular shape and an air-impermeable duct wall coupled to an outer surface of the foam-filled honeycomb core structure.
By using one of the conduits described herein, the environmental control system can more effectively meet acoustic design requirements, achieve better thermal performance, achieve lower weight and volume configurations, and reduce costs.
Drawings
FIG. 1 is a block diagram illustrating an example of a conduit;
FIG. 2 is a block diagram of an aircraft including an example of an environmental control system including one of the conduits of FIG. 1;
FIG. 3 is a diagram illustrating a perspective view of an example of the environmental control system of FIG. 2;
FIG. 4A is a diagram illustrating a cross-sectional view of an example of one of the conduits of FIG. 1;
fig. 4B is a diagram illustrating a cross-sectional view of an example of another pipe of fig. 1;
FIG. 5A is a diagram illustrating a side view of an example of the conduit of FIG. 4A;
FIG. 5B is a diagram illustrating a cross-sectional view of the conduit of FIG. 5A;
FIG. 6 is a diagram illustrating a cross-sectional view of another example of the conduit of FIG. 4A;
FIG. 7 is a diagram illustrating a cross-sectional view of another example of the conduit of FIG. 4A;
FIG. 8A is a diagram illustrating a cross-sectional view of an example of the conduit of FIG. 4B including a sleeve;
FIG. 8B is a diagram illustrating a cross-sectional view of an example of the conduit of FIG. 4B including an internal coupler;
FIG. 9 is a diagram illustrating a cross-sectional view of a particular example of the conduit of FIG. 4B;
FIG. 10 is a diagram showing a detailed cross-sectional view of a pipe including an example of an inner coupler;
fig. 11A is a diagram illustrating a cross-sectional view of an example of a duct including a foam-filled honeycomb core structure;
FIG. 11B is a diagram showing a foam-filled honeycomb core structure including multiple cavities of the conduit of FIG. 11A;
FIG. 11C is a diagram showing a foam-filled honeycomb core structure of foam including the conduit of FIG. 11A;
FIG. 11D is a diagram showing a foam-filled honeycomb core structure and air-impermeable duct walls of the duct of FIG. 11A;
FIG. 12A is a diagram illustrating a cross-sectional view of an example of the conduit of FIG. 11A including an inner layer;
fig. 12B is a diagram showing a specific example of the pipe of fig. 12A;
FIG. 12C is a diagram illustrating another example of the conduit of FIG. 12A;
FIG. 12D is a diagram illustrating another example of the conduit of FIG. 12A;
fig. 13 is a diagram showing an example of perforation of a rigid tube of a pipe.
FIG. 14 is a flow chart of one example of a method of manufacturing a pipe;
FIG. 15 is a flow chart of another example of a method of manufacturing a tube;
FIG. 16 is a flow chart of another example of a method of manufacturing a tube;
FIG. 17 is a flow chart of an example of a method of pipe manufacturing and maintenance;
FIG. 18 is a block diagram illustrating an example of a vehicle including a duct; and
FIG. 19 is a diagram illustrating a top view of an example of an aircraft including the environmental control system of FIG. 2.
Detailed Description
The disclosed examples provide a duct that absorbs sound for use in an environmental control system. A method of manufacturing a pipe is also disclosed. The pipe according to certain aspects disclosed herein may be used as a noise attenuating muffler and may reduce the use of dedicated noise attenuating mufflers in environmental control systems. For example, conventional piping and noise attenuating mufflers may be replaced with the disclosed piping.
In a first example, a first conduit (e.g., a first type of conduit) includes a rigid gas permeable tube of composite material forming an inner surface or wall of the first conduit. The first pipe further includes an insulation layer (e.g., foam or felt) and a non-rigid outer liner. The non-rigid outer liner seals the duct to form an air-impermeable duct wall and provides an outer or second layer of thermal and acoustic insulation. In contrast to conventional ducts that include a rigid outer wall (or a rigid outer wall encased in a non-rigid insulating material), the first duct includes a non-rigid outer liner that seals the duct and provides insulation (and some sound absorption). The first pipe is lighter and less expensive to produce than conventional pipes.
In a second example, a second pipe (e.g., a second type of pipe) includes a rigid tube of composite material and an insulating layer disposed within the rigid tube. The second conduit also includes a biasing member (e.g., a spring) disposed within the rigid tube that secures the insulation layer against the inner surface of the rigid tube. Similar to the first conduit, the second conduit has one rigid component, i.e., an outer layer or tube. Conventional ducts typically have two or more rigid components. Thus, the second pipe is lighter and less expensive to produce than conventional pipes.
In a third example, a third conduit (e.g., a third type of conduit) includes a foam-filled honeycomb core structure having a tubular shape and an air-impermeable conduit wall coupled to an outer surface of the foam-filled honeycomb core structure. The foam-filled honeycomb core structure includes a plurality of cavities filled with foam. An air-impermeable duct wall (e.g., a thermoplastic film or a rigid composite tube) is coupled to the foam-filled honeycomb core structure to seal the third duct. In some examples, the third conduit further comprises an inner layer. For example, the third conduit may also comprise a rigid gas permeable tube of composite material, or a foam layer as an inner layer. The third conduit is stronger and lighter than conventional conduits because of its "insulating layer," the foam filling the honeycomb core structure, providing structural support and stability. The foam-filled honeycomb core structure enables the air-impermeable duct walls to be non-rigid outer liners (e.g., thermoplastic films) or relatively thin composite layers (as compared to conventional ducts where the outer layers provide structural stability). For example, the composite may be only one ply or two plies thick.
A technical effect of the examples described herein enables an environmental control system to be lighter, smaller, or less expensive than other conduits that do not have at least some of these features. Thus, a vehicle including such an environmental control system may be lighter, smaller, and less expensive.
Fig. 1 shows a block diagram 100 of an example of a pipe 102. The conduit 102 may be included in an environmental control system (e.g., the environmental control system 202 of fig. 2). The conduit 102 may be included in a vehicle (e.g., the aircraft 200 of fig. 2).
The conduit 102A includes a rigid gas permeable tube 112 (also referred to herein as rigid gas permeable tube 112) of a composite material, an insulating layer 114, and a non-rigid insulating layer 116. The composite rigid gas permeable tubing 112 comprises or corresponds to a composite tube formed of "open" braided composite or rigid perforated tubing 136. Loosely woven composites include composites having an arrangement or pattern of fibers with loose loops. Examples of loose loop arrangements include a leno weave arrangement (i.e., a gauze weave or a cross weave arrangement). The leno weave arrangement is a plain weave in which adjacent "warp" fibers twist around successive "weft" fibers to form helical pairs, effectively "locking" each weft in place. The loosely woven composite tube 132 includes (e.g., is formed from) a number of plies of loosely woven composite such that when the loosely woven composite is cured, the loosely woven composite tube 132 contains openings through which air may pass (i.e., is air permeable). The air permeability of the loosely woven composite tube 132 enables the tube 102A to absorb sound like a noise attenuating silencer.
Rigid perforated tube 136 includes a plurality of perforations (e.g., perforations 1312 of fig. 13) such that air may pass through the perforations and rigid perforated tube 136. In some examples, the rigid perforated tube 136 includes or corresponds to a composite tube formed of a "close" braided composite.
Insulation layer 114 is coupled to the outer surface of rigid gas permeable tubing 112 and comprises an intermediate layer of tubing 102A. The insulating layer 114 is configured to provide thermal insulation and/or sound absorption. The insulating layer 114 comprises a foam or felt layer. As illustrative, non-limiting examples, the insulating layer 114 includes an open cell foam 152 or an aramid felt 154.
In some examples, the open-cell foam 152 has a spiral wound configuration. For illustration, the open-cell foam 152 is in the form of a strip or triangle and is wrapped around the exterior of the composite rigid gas permeable tubing 112. As one illustrative, non-limiting example, the open-cell foam 152 includes or corresponds to melamine foam. The aramid felt 154 includes aramid fibers, such as meta-aramid fibers, para-aramid fibers, or combinations thereof, that are entangled, coalesced, and/or pressed together. As one illustrative, non-limiting example, aramid felt 154 may include or correspond to meta-aramid felt (e.g., NOMEX felt material — NOMEX is a registered trademark of DuPont) or para-aramid felt.
The non-rigid insulating layer 116 is in contact with the insulating layer 114, and the non-rigid insulating layer 116 forms an air-impermeable duct wall. The non-rigid insulation layer 116 is configured to provide insulation and seal the pipe 102A. In some examples, the non-rigid insulating layer 116 absorbs sound. The non-rigid insulation layer 116 includes or corresponds to a layer of thermoplastic film 162 or a layer of high quality fabric 164 that serves as an outer liner for the conduit 102A. The thermoplastic film 162 layer may include a Polyetherketoneketone (PEKK) film, a Polyetheretherketone (PEEK) film, polyvinyl fluoride (PVF), a non-flammable material pressure sensitive tape, or a combination thereof (e.g., a first layer of PEKK film and a second layer of PEEK film). In some examples, the thermoplastic film 162 layers include one to two layers or plies of thermoplastic material. High quality fabrics 162 as used herein include materials made from natural or synthetic fibers that produce fabrics having an areal density (e.g., basis weight) of greater than about 15 ounces per square yard. This areal density provides sound blocking (e.g., reduces or prevents leakage noise through the cross-section of the pipe), thermal insulation, and can be used as an air-impermeable liner.
The conduit 102B includes a biasing member 122, an insulating layer 124, and a rigid tube of composite material 126. The rigid tube of composite material 126 is configured to support the conduit 102B. The rigid tube of composite material 126 may include or correspond to an arrangement of composite material that is impermeable and forms an air-impermeable external conduit wall.
The biasing member 122 is disposed within the rigid tube of composite material 126 and is configured to confine the insulating layer 124 within the rigid tube of composite material 126. For example, the biasing member 122 applies a force (e.g., a radially outward force) that secures and restrains the insulation layer 124 against the inner surface of the rigid tube of composite material 126. In some examples, the biasing member 122 includes or corresponds to a spring, such as the spring 822 of fig. 8. As one illustrative, non-limiting example, the biasing member 122 is a helical compression spring.
The insulating layer 124 is configured to absorb sound and provide thermal insulation. The insulating layer 124 includes an open cell foam 152, an aramid felt 154, a high quality fabric 164, or a combination thereof. As one illustrative, non-limiting example, the insulating layer 124 comprises a NOMEX felt layer.
The conduit 102C includes a foam-filled honeycomb core structure 144 and an air-impermeable conduit wall 146. The foam filled honeycomb core structure 144 has a tubular shape. For purposes of illustration, the foam-filled honeycomb core structure 144 defines an inlet and an outlet opposite the inlet. The foam-filled honeycomb core structure 144 has an inner surface and an outer surface opposite the inner surface. The foam-filled honeycomb core structure 144 includes a core structure 172, the core structure 172 defining a plurality of cavities 174, as shown in fig. 11B-11D. The foam-filled honeycomb core structure 144 includes foam 176 within the plurality of cavities 174. The foam 176 may include or correspond to the open cell foam 152, the closed cell foam 134, or a combination thereof.
An air-impermeable duct wall 146 is coupled to an outer surface of the foam-filled honeycomb core structure 144. The air-impermeable duct wall 146 is configured to seal the duct 102C. The air-impermeable duct wall 146 may be flexible or rigid. For example, the air impermeable duct wall 146 may include or correspond to a layer of thermoplastic film 162, a layer of high quality fabric 164, or a rigid tube 166. The rigid tube 166 may be made of composite materials, plastics, metals, or combinations thereof.
In some examples, the conduit 102C further includes an inner layer coupled to an inner surface of the foam-filled honeycomb core structure 144. For example, the duct 102C also includes a loose weave composite tube 132, a layer of closed cell foam 134, or a rigid perforated tube 136 coupled to the inner surface of the foam filled honeycomb core structure 144.
In some examples, the conduits 102A-102C include an adhesive material (e.g., adhesive material 522 of fig. 5) to couple a first conduit to a second conduit or another component via a coupler (e.g., sleeve 512 of fig. 5 or internal coupler 812 of fig. 8), as further described herein. Additionally or alternatively, the conduit 102A includes a tape (e.g., tape 622 of fig. 6) coupled to the insulating layer 114, the non-rigid insulating layer 116, or both. Additionally, the conduit 102B may include a tape (e.g., tape 622 of fig. 6) coupled to the insulating layer 124. The conduits 102A-102C may be manufactured by the exemplary manufacturing method described with reference to fig. 14-16.
In operation, the conduits 102A-102C are configured to convey treated air, provide insulation, provide sound absorption, provide sound blocking, and provide structural integrity for positive and negative pressure applications. The operation of the conduits 102A-102C is further described with reference to FIG. 3.
FIG. 2 is a block diagram of an aircraft 200, the aircraft 200 including an example of an Environmental Control System (ECS)202, the Environmental Control System (ECS)202 including one of the conduits 102A-102C of FIG. 1. In other examples, ECS202 is included on other vehicles (e.g., rockets, helicopters, automobiles, buses, trains, ships, submarines, etc.).
As shown in fig. 2, ECS202 includes ductwork 212, air conditioning unit 214, intake port 222, and exhaust port 224. The conduit system 212 is configured to provide a treated fluid (e.g., treated air 352 of fig. 3) to passengers of the aircraft 200. The piping system 212 includes one or more pipes. As shown in fig. 2, the piping system 212 includes a first zone pipe 232, a lift pipe 234, a second zone pipe 236, and an outlet port 238.
One or more of the first zone conduits 232, the lifting conduits 234, and the second zone conduits 236 may include the conduits 102A-102C of fig. 1. As shown in the example of FIG. 2, the first zone conduits 232 include at least one of the conduits 102A-102C of FIG. 1. The first zone conduit 232, the lifting conduit 234, and the second zone conduit 236 are configured to convey fluid through the conduit system 212.
The outlet port 238 is configured to provide fluid to the occupant. For example, the outlet port 238 includes or corresponds to a cabin or passenger vent. The outlet port 238 may be controlled (e.g., opened or closed) by a passenger. The outlet port 238 may be coupled to the first zone conduit 232, the lift conduit 234, the second zone conduit 236, or a combination thereof.
The air conditioning unit 214 is in fluid communication with the ductwork 212 and is configured to condition or process a fluid (e.g., air) within the ECS 202. The intake port 222 is in fluid communication with the piping system 212 and is configured to intake or receive fluid (e.g., air) into the ECS 202. For example, the intake port 222 may draw in fluid (e.g., ambient air or non-pressurized air) from within the aircraft 200 (e.g., a pressurized cabin and/or cabin of the aircraft 200) or from outside the aircraft 200.
The exhaust port 224 is in fluid communication with the piping system 212 and is configured to exhaust or consume a fluid (e.g., air). For example, exhaust port 224 may exhaust fluid outside of aircraft 200 or from ECS202 (e.g., exhaust fluid to a filter or another system of aircraft 200). Although the ECS202 of fig. 2 includes an air conditioning unit 214, in other examples, the ECS202 may include other components (e.g., heaters, electrical equipment, exhaust systems, fans, vents, etc., or combinations thereof) in addition to or in place of the air conditioning unit 214. The operation of the ECS202 of fig. 2 is described with reference to fig. 3.
Fig. 3 is a diagram 300 illustrating a particular example of the Environmental Control System (ECS)202 of fig. 2. In fig. 3, first zone duct 232 is located below cabin 312 of aircraft 200 (e.g., in zone 314 below floor 322 of cabin 312), lift duct 234 is located between cabin 312 and an exterior (e.g., skin) of aircraft 200, and second zone duct 236 is located above a ceiling 324 of cabin 312 (e.g., in a roof 316 of aircraft 200).
During operation, treated air 352 from the air conditioning unit 214 (and/or the intake port 222) is received by the first zone duct 232. The first zone duct 232 routes the treated air 352 through the first zone duct 232 and to the lift duct 234. As the treated air 352 moves through the first zone ducts 232, the treated air 352 generates noise. Additionally or alternatively, the noise is generated by a fan, a duct geometry, a flow control device, an object in the flow path of the treated air 352, or a combination thereof. The first zone ducts 232 attenuate noise and provide insulation such that heat from ambient air (e.g., air outside the ECS 202) is not transferred to the treated air 352 and heat from the treated air 352 is not transferred to the ambient air.
The lift ducts 234 convey the treated air 352 through the lift ducts 234 and to the second zone ducts 236. In some examples, the lift tube 234 also delivers the treated air 352 to the outlet port 238 where the treated air 352 may be controlled by the occupant. As the treated air 352 moves through the lift tube 234, the treated air 352 generates noise. The riser 234 attenuates noise and provides insulation.
The second zone ducting 236 conveys the treated air 352 through the second zone ducting 236 and to the air conditioning unit 214 (and/or the exhaust port 224). In other examples, second zone duct 236 delivers treated air 352 to outlet port 238 where treated air 352 may be controlled by the occupant. As the treated air 352 moves through the second zone ducts 236, the treated air 352 generates noise. The second zone conduits 236 attenuate noise and provide insulation.
As shown in fig. 3, the exemplary ECS202 has no distinct noise attenuating mufflers (e.g., zone mufflers). For example, the ECS202 does not include a duct portion having an external noise attenuating muffler surrounding the duct portion and/or duct and a dedicated noise attenuating muffler combination portion configured to absorb sound above or below the chamber 312, as in conventional ECS.
Fig. 4A and 4B show cross-sectional views of an example of the conduit 102A and an example of the conduit 102B. In fig. 4A and 4B, examples of the pipes 102A and 102B are curved. In other examples, such as in fig. 5 and 8, the conduits 102A-102C are straight. In fig. 4A, the conduit 102A includes a rigid gas permeable tube 112, an insulating layer 114, and a non-rigid insulating layer 116. In fig. 4B, the conduit 102B includes a biasing member 122, an insulating layer 124, and a rigid tube of composite material 126. Further examples of conduits 102A and 102B are shown in fig. 5A, 5B, 6, 7, 8A, 8B, 9, and 10.
Fig. 5A and 5B illustrate side and cross-sectional views (e.g., longitudinal cross-sections) of a particular example of a conduit 102A. In fig. 5A and 5B, the conduit 102A includes a rigid gas permeable tube 112, an insulating layer 114, a non-rigid insulating layer 116, and a sleeve 512. The sleeve 512 is coupled to the outer surface of the rigid gas permeable tubing 112 by an adhesive material 522. Sleeve 512 is configured to overlap a portion of one end of rigid gas permeable tubing 112 of conduit 102A and overlap a portion of one end of second conduit 102A to couple conduit 102A and second conduit 102A in fluid communication.
Adhesive material 522 comprises a material configured to bond sleeve 512 to rigid gas permeable tubing 112. For example, the adhesive material 522 includes silicone or a pressure sensitive adhesive. As one illustrative, non-limiting example, the adhesive material 522 includes room temperature-vulcanized (RTV) silicone. As shown in fig. 5A, the adhesive material 522 is in contact with the rigid gas permeable tubing 112, the rigid gas permeable tubing 112 extending beyond the insulating layer 114 and the non-rigid insulating layer 116.
As shown in fig. 5A, the sleeve 512 is smaller (e.g., has a smaller diameter) than the conduit 102A (e.g., its non-rigid insulation layer 116 diameter). In other examples, the size of the sleeve 512 is the same as the size of the conduit 102A (e.g., the diameter of its non-rigid insulation layer 116) or larger than the size of the conduit 102A.
Fig. 5B depicts a cross-sectional view (e.g., a longitudinal cross-section) of the conduit 102A of fig. 5A. In fig. 5B, area 532 represents a portion of the conduits 102A where an adhesive tape (e.g., tape 622 of fig. 6) may be used to seal a joint or coupling between the conduits 102A. For example, tape (not shown) may be used to seal the edge between the conduit 102A and the sleeve 512, as further described with reference to fig. 6. In other examples, the conduit 102A includes an internal coupler (e.g., the internal coupler 812 of fig. 8) to couple to the second conduit 102A, as described with reference to fig. 8 and 10.
Fig. 6 is a diagram 600 illustrating a cross-sectional view (e.g., a transverse or circumferential cross-section) of another example of a conduit 102A. In fig. 6, the conduit 102A includes a loosely woven composite tube 132 for the rigid gas permeable tubing 112, a layer of aramid felt 154 for the insulation layer 114, and a layer of thermoplastic film 162 for the non-rigid insulation layer 116. In the example shown in fig. 6, the aramid felt 154 layer comprises a ply of NOMEX felt and the thermoplastic film 162 layer comprises one or two (e.g., plies) of PEEK film.
The aramid felt 154 layer and the thermoplastic film 162 layer each form a seam 612. For example, aramid felt 154 is wrapped around loosely woven composite tube 132 and forms seam 612, and thermoplastic film 162 is wrapped around aramid felt 154 layers and forms seam 612.
In fig. 6, the duct 102A also includes tape 622 located adjacent to the seam 612 (e.g., over the seam 612). The tape 622 is configured to restrain the insulating layer 114 (i.e., the aramid felt 154 layer), the non-rigid insulating layer 116 (i.e., the thermoplastic film 162 layer), or both. In some examples, the tape 622 includes or corresponds to a pressure sensitive tape. As one illustrative, non-limiting example, the tape 622 comprises a Metalized Polyetheretherketone (MPEEK) material. In other examples, the non-rigid insulation layer 116 includes a layer of high quality fabric 164. For example, the non-rigid insulation layer 116 includes one to two layers (e.g., plies) of high quality fabric 164 wrapped around the layer of aramid felt 154.
Fig. 7 is a diagram 700 illustrating a cross-sectional view (e.g., a transverse or circumferential cross-section) of another example of a conduit 102A. In fig. 7, the duct 102A includes a loosely woven composite tube 132 for the rigid gas permeable tubing 112, a layer of open cell foam 152 for the insulation layer 114, and a layer of thermoplastic film 162 for the non-rigid insulation layer 116. In the example shown in fig. 6, the layer of open-cell foam 152 comprises a spirally wound layer of melamine foam, and the layer of thermoplastic film 162 comprises one or two (e.g., plies) of a film of PEEK. In some examples, the spiral wound melamine foam layer comprises multiple sheets (e.g., three to four sheets) of compressed melamine foam that is spirally wound around the loosely woven composite tube 132.
In contrast to the conduit 102A of fig. 6, which includes a layer of aramid felt 154, the conduit 102A of fig. 7 includes a layer of open-cell foam 152. The open-cell foam 152 layer provides higher heat resistance than aramid felt 154 or NOMEX foam. The open cell foam 152 provides sound absorption similar to aramid felt 154 at a lower cost and weight. The aramid felt 154 provides higher sound absorption (e.g., absorption and reduction of leakage noise) and transmission losses (e.g., noise reduction from the inlet of the conduit 102A to the outlet of the conduit 102A) than a similar quality of open cell foam 152.
Fig. 8A and 8B each show a cross-sectional view (e.g., a longitudinal cross-section) of an example of a pipe 102B that includes a coupler. In fig. 8A and 8B, the conduit 102B includes a spring 822 for the biasing member 122, a layer of aramid felt 154 for the insulation layer 124, and a rigid tube of composite material 126. In the example shown in fig. 8A and 8B, the springs 822 comprise helical compression springs and the aramid felt 154 layer comprises a ply of NOMEX felt.
Referring to fig. 8A, a first example of a conduit 102B including a sleeve 512 is shown. In fig. 8A, sleeve 512 (e.g., an external coupler) is in contact with the exterior of conduit 102B, which is the exterior surface of the rigid tube of composite material 126, as opposed to sleeve 512 of fig. 5A, where sleeve 512 of fig. 5A is in contact with the exterior surface of the rigid gas permeable tube 112 of the composite material of conduit 102A.
In fig. 8B, a second example of a pipe 102B includes an internal coupler 812. In some examples, the internal coupler 812 includes threads (not shown), a rim 814, or a combination thereof to couple and secure portions of the pipe 102B together. As shown in fig. 8B, the inner coupler 812 includes a rim 814 (e.g., a protrusion) that engages a surface (inner surface) of the second conduit 102B or sleeve 512. The rim 814 applies a force to hold the tubes 102B together and creates a friction force that resists the tubes 102B from disengaging. For example, the rim 814 exerts a force on the sleeve 512, which is coupled to the pipe 102B by a hose clamp or a plastic zipper system (zip tie). The internal coupler 812 is further described with reference to fig. 10.
Although the conduit 102B is shown in fig. 8A and 8B as having two sleeves 512 or two internal couplers 812, as shown, in other examples, a particular conduit (e.g., one of the conduits 102A-102C) may include one sleeve 512 and one internal coupler 812.
Fig. 9 is a diagram 900 illustrating a cross-sectional view (e.g., a transverse or circumferential cross-section) of a particular example of a pipe 102B. In fig. 9, the conduit 102B includes a spring 822 for the biasing member 122, a layer of aramid felt 154 for the insulation layer 124, and a rigid tube of composite material 126. In the example shown in fig. 9, the aramid felt 154 layer comprises a ply of NOMEX felt.
Fig. 10 is a diagram 1000 illustrating a detailed cross-sectional view (longitudinal cross-section) of the inner coupler 812 of fig. 8. In fig. 10, the inner coupler 812 is a "reducer," i.e., the inner coupler 812 reduces the outer diameter 1012, 1014 of the pipe 102B. To illustrate, a first outer diameter 1012 of the first pipe 102B is greater than a second outer diameter 1014 of an inner portion of the inner coupler 812 (and of the second pipe 102B), the second pipe 102B being coupled to the pipe 102B via the inner coupler 812. An outer portion of the inner coupler 812 (e.g., a portion near the rim 814) has an outer diameter, a third outer diameter 1016 that is less than a first outer diameter 1012 of the first pipe 102B and a second outer diameter 1014 of an inner portion of the inner coupler 812. In some examples, the second conduit 102B and/or the sleeve (e.g., sleeve 512) is coupled to the inner coupler 812 and contacts the rim 814. The second conduit 102B and/or the sleeve 512 may be secured to the first conduit 102B by a hose clamp or a plastic zipper system.
In fig. 10, the inner diameter 1018 of the conduit 102B and the second conduit 102B remain the same. In other examples, the internal coupler 812 has an inner diameter 1018 that is less than the inner diameter 1018 of the pipe 102B, and the internal coupler 812 reduces the inner diameter 1018 of the second pipe 102B in addition to or as an alternative to reducing the first outer diameter 1012 of the pipe 102B. The inner coupler 812 comprises a polymer, composite, metal, or combination thereof.
Fig. 11A-11D illustrate a particular example of a conduit 102C and its foam-filled honeycomb core structure 144. Fig. 11A is a diagram showing a cross-sectional view of the pipe 102C. In fig. 11A, a conduit 102C has a foam-filled honeycomb core structure 144 and an air-impermeable conduit wall 146. The foam filled honeycomb core structure 144 includes a plurality of cavities 174 as shown in fig. 11B.
Fig. 11B depicts a surface of the foam-filled honeycomb core structure 144 that defines a plurality of cavities 174. The plurality of cavities 174 have a hexagonal shape (e.g., a honeycomb shape). In other examples, one or more of the plurality of cavities 174 have other shapes, such as circular, rectangular, square, pentagonal, octagonal, other shapes that can tessellate, or combinations thereof. The plurality of cavities 174 are shown in fig. 11B as extending through the foam-filled honeycomb core structure 144, i.e., the plurality of cavities 174 correspond to through-holes and are defined by two surfaces of the foam-filled honeycomb core structure 144. In other examples, the plurality of cavities 174 do not extend through the foam-filled honeycomb core structure 144. In one particular example, each surface of the foam filled honeycomb core structure 144 defines a respective plurality of cavities 174.
Fig. 11C depicts the foam 176 filling the plurality of cavities 174 of the honeycomb core structure 144. As shown in fig. 11C, the foam 176 (e.g., closed cell foam 134 or open cell foam 152) extends to the surface of the foam-filled honeycomb core structure 144. In other examples, the foam 176 terminates or extends beyond the surface of the foam-filled honeycomb core structure 144 before the foam fills the surface of the honeycomb core structure 144. The foam 176 may be grown in situ (i.e., within the plurality of cavities 174) or may be inserted into the plurality of cavities 174.
The foam-filled honeycomb core structure 144 (e.g., portions thereof) includes one or more layers (e.g., air-impermeable duct walls 146) coupled to a surface of the foam-filled honeycomb core structure 144 that defines a plurality of cavities 174, as shown in fig. 11D. In one particular example, the air-impermeable duct wall 146 comprises a composite material.
Fig. 12A shows a cross-sectional view of an example of a pipe 102C including an inner layer. In fig. 12A, the conduit 102C includes a foam-filled honeycomb core structure 144, an air-impermeable conduit wall 146, and one of the inner layers described with reference to fig. 1. For example, the pipe 102C includes one of a loosely woven composite tube 132, a layer of closed cell foam 134, or a rigid perforated tube 136.
Fig. 12B depicts the example of the conduit 102C of fig. 12A with the foam-filled honeycomb core structure 144 positioned (e.g., sandwiched) between two layers. In fig. 12B, a foam filled honeycomb core structure 144 is positioned between the loosely woven composite tube 132 and the layer of thermoplastic film 162.
Fig. 12C depicts another example of the duct 102C of fig. 12A, wherein the foam-filled honeycomb core structure 144 is positioned between the layer of closed cell foam 134 and the layer of thermoplastic film 162.
Fig. 12D depicts another example of the conduit 102C of fig. 12A, wherein the foam-filled honeycomb core structure 144 is positioned between the rigid perforated tube 136 and the layer of thermoplastic film 162.
Fig. 13 is a diagram 1300 illustrating an example of perforations 1312 of the rigid tube 166 of the conduit 102C. As shown in fig. 13, the conduit 102C is curved and the perforations 1312 have a circular cross-section. In other examples, the conduit 102C is straight and/or the perforations 1312 have a non-circular cross-section, such as an elliptical cross-section, a rectangular cross-section, a square cross-section, a triangular cross-section, or a hexagonal cross-section. In some examples, the perforations 1312 are arranged in a pattern. For example, the perforations 1312 may be arranged in an asymmetrical pattern or a symmetrical pattern. To illustrate, when the perforations 1312 are symmetrical, the perforations 1312 may be symmetrical with respect to an axis or curvature of the conduit 102C.
Perforations 1312 are configured to allow air and/or sound waves to pass from the interior of rigid tube 166 to another layer of conduit 102C. The perforations 1312 of the rigid tube 166 enable the duct 102C to function like a muffler, i.e., reduce the sound generated by air moving through the duct 102C and ECS. To illustrate, when the sound wave propagates to the perforations 1312, a portion of the sound wave passes through the perforations 1312 to the insulation or material of the pipe 102C where it is absorbed.
In some examples, perforations 1312 are sized to cause destructive interference (i.e., to reduce noise by canceling sound waves generated by air moving through duct 102C). To illustrate, as the sound waves propagate to the perforations 1312, another portion of the sound waves are reflected back into the interior of the rigid tube 166. Another portion of the sound wave may cause destructive interference with another sound wave and may cancel at least a portion of the other sound wave. The size of perforations 1312 is based on the size (e.g., length and/or diameter) of rigid tube 166, the velocity of the air, the pressure of the air, or a combination thereof.
Fig. 14 illustrates a particular example of a method 1400 of manufacturing a pipe (e.g., the pipe 102A of fig. 1). The method 1400 includes, at 1402, applying an insulating material to an outer surface of a rigid gas permeable tube of a composite material to form an insulating layer on the outer surface of the rigid gas permeable tube. For example, the insulating layer may include or correspond to the insulating layer 114, the open-cell foam 152, or the aramid felt 154 of fig. 1. The rigid gas permeable tubing of the composite material may comprise or correspond to the rigid gas permeable tubing 112 of the composite material of fig. 1. To illustrate, the insulation layer 114 is formed by wrapping an insulating material (e.g., open cell foam 152, aramid felt 154, or both) around the exterior or outer face of the composite rigid gas permeable tubing 112. In one particular example, the composite material of the rigid gas permeable tubing 112 comprises a textile material having a leno weave arrangement. In one particular example, after the application of the insulating material, a leak check or test is performed on the combined rigid gas permeable tubing and insulating layer.
The method 1400 further includes, at 1404, applying a non-rigid insulating material to an outer surface of the insulating layer to form a non-rigid insulating layer in contact with the insulating layer, the non-rigid insulating layer forming an air-impermeable duct wall. For example, the non-rigid insulation layer may include or correspond to the non-rigid insulation layer 116, the thermoplastic film 162, or the high quality fabric 164 of fig. 1. To illustrate, the non-rigid insulation layer is formed by wrapping a non-rigid insulation material (e.g., a thermoplastic film 162 or a high quality fabric 164) around the exterior or outer face of the insulation layer 114.
In some examples, the rigid gas permeable tubing comprises rigid perforated tubing of composite material. In such an example, the method 1400 includes, prior to applying 1402 the insulating material to the outer surface of the rigid gas permeable tubing, creating 1412 a rigid perforated tubing. In some such examples, the producing 1412 includes curing 1422 the composite material into a rigid tube and producing 1424 perforations in the rigid tube to form a rigid perforated tube. To illustrate, the composite material is applied to the outer surface of a tubular tool or mandrel and cured by applying heat, light, pressure (plenum pressure or vacuum pressure), or a combination thereof to the composite material to form a rigid tube. Perforations are created in the rigid tube by machining the rigid tube to form a rigid perforated tube of composite material.
In other examples, the producing 1412 includes applying the composite material onto a tool to form a rigid perforated pipe such that perforations are formed during curing of the composite material. For example, a tool used as a layup surface for composite materials includes protrusions such that when the composite material is cured, the protrusion housings perforate in a rigid perforated pipe.
In some examples, the method 1400 further includes applying tape to the insulation layer, the non-rigid insulation layer, or both, at 1414, to secure the insulation layer to the rigid gas permeable tubing, to secure the non-rigid insulation layer to the insulation layer, or both. For example, the tape includes or corresponds to tape 622 of fig. 6. To illustrate, a 1-ply MPEEK tape is placed along the seam 612 of the insulation layer 114 and the non-rigid insulation layer 116 to secure the layers and seal the pipe 102A.
FIG. 15 shows another example of a method 1500 of manufacturing a pipe (e.g., the pipe 102B of FIG. 1). The method 1500 includes inserting 1502 an insulating material into a rigid tube of composite material to form an insulating layer within the rigid tube, the insulating layer in contact with an inner surface of the rigid tube. For example, the insulating layer may include or correspond to the insulating layer 124, the open-cell foam 152, the aramid felt 154, or the high-quality fabric 164 of fig. 1. The rigid tube of composite material may comprise or correspond to the rigid tube of composite material 126 of fig. 1. To illustrate, the insulation layer 124 is formed by wrapping an insulation material (e.g., open cell foam 152, aramid felt 154, high quality fabric 164, or a combination thereof) around the inside or interior of the rigid tube of composite material 126.
The method 1500 also includes inserting a biasing member into the rigid tube of composite material at 1504 to secure the insulating layer within the rigid tube. For example, the biasing member may include or correspond to the biasing member 122 or spring 822 of fig. 8. To illustrate, the biasing member 122 is inserted inside or within the rigid tube of composite material 126 through an inlet or outlet of the rigid tube of composite material 126. In some such examples, the insulating material may be coupled or secured to the rigid tube of composite material 126 by tape 622, or the insulating material may be coupled to itself by tape 622 to form the tubular shape and insulating layer 124.
In some examples, the method 1500 includes, prior to inserting the insulating material, coupling 1512 the insulating material to a biasing member. To illustrate, an insulating material (e.g., open cell foam 152, aramid felt 154, high quality fabric 164, or a combination thereof) is wrapped around or applied to the exterior or outside of the biasing member 122 to form the insulating layer 124, and then the combined insulating layer 124 and biasing member 122 are inserted into a rigid tube of composite material 126 to form the conduit 102B. For example, the insulating layer 124 and the biasing member 122 are inserted as a unitary piece into a rigid tube of composite material 126. In some such examples, the insulating material may be coupled or secured to the biasing member 122 by adhesive tape 622. Alternatively, the adhesive material 522 couples or secures the insulating material to the biasing member 122, or the biasing member 122 (e.g., the spring 822) is threaded through the insulating material to couple or secure the insulating material to the biasing member 122.
FIG. 16 illustrates a particular example of a method 1600 of manufacturing a pipe (e.g., the pipe 102B of FIG. 1). Method 1600 includes, at 1602, creating a honeycomb core structure having a tubular shape, the honeycomb core structure including a plurality of hexagonal cavities. For example, the honeycomb core structure may include or correspond to the core structure 172 of fig. 1, and the plurality of hexagonal cavities may include or correspond to the plurality of cavities 174. For purposes of illustration, the core structure 172 is formed in a tubular shape and its surface defines a plurality of cavities 174. As illustrative, non-limiting examples, the composite material may be cured to form core structure 172, or the metal may be processed to form core structure 172.
The method 1600 also includes filling a plurality of hexagonal cavities of the honeycomb core structure with foam at 1604 to produce a foam-filled honeycomb core structure. For example, the foam may include or correspond to the foam 176, closed cell foam 134, or open cell foam 152 of fig. 1. The foam-filled honeycomb core structure may include or correspond to the foam-filled honeycomb core structure 144 of fig. 1.
In some examples, filling 1604 the plurality of hexagonal cavities of the honeycomb core structure with foam includes depositing 1612 foam in the plurality of hexagonal cavities. To illustrate, foam 176 is inserted or deposited into the plurality of cavities 174. In other examples, filling 1604 the plurality of hexagonal cavities of the honeycomb core structure with foam includes generating 1614 foam within the plurality of hexagonal cavities. To illustrate, a coating is applied (e.g., sprayed) to the plurality of cavities 174, and heat is applied to the coating to create or grow foam 176 in the plurality of cavities 174.
The method 1600 also includes coupling the air-impermeable conduit wall to an outer surface of the foam-filled honeycomb core structure at 1606. For example, the air-impermeable conduit wall may comprise or correspond to the air-impermeable conduit wall 146, the thermoplastic film 162, or the rigid tube 166 of FIG. 1. To illustrate, the air impermeable duct wall 146 is formed by wrapping a thermoplastic film 162 around the outside or exterior of the foam filled honeycomb core structure 144. Alternatively, the air-impermeable duct wall 146 is formed by coupling a rigid tube 166 to the exterior or outside of the foam-filled honeycomb core structure 144.
In some examples, the method 1600 further includes coupling 1622 a closed-cell rigid perforated tube of composite material to an inner surface of the foam-filled honeycomb core structure. To illustrate, a rigid perforated tube of composite material is coupled to the inner surface of the foam-filled honeycomb core structure 144. In other examples, the method 1600 further includes coupling 1624 closed cell foam to an inner surface of the foam-filled honeycomb core structure. To illustrate, the closed cell foam 134 is coupled to the inner surface of the foam-filled honeycomb core structure 144.
The method 1400 of fig. 14, the method 1500 of fig. 15, and/or the method 1600 of fig. 16 may be initiated or controlled by an Application Specific Integrated Circuit (ASIC), a processing unit (e.g., a Central Processing Unit (CPU)), a controller, another hardware device, a firmware device, a Field Programmable Gate Array (FPGA) device, or any combination thereof. As one example, the method 1400 of fig. 14 may be initiated or controlled by one or more processors (e.g., one or more processors included in a control system). In some examples, a portion of the method 1400 of fig. 14 may be combined with the second portion of one of the method 1500 of fig. 15 or the method 1600 of fig. 16. In addition, one or more of the operations described with reference to fig. 14-16 may be optional and/or may be performed in a different order than illustrated or described. Two or more of the operations described with reference to fig. 14-16 may be performed at least partially simultaneously.
Referring to fig. 17 and 18, examples of the present disclosure are described in the context of a vehicle manufacturing and service method 1700 as shown in the flowchart of fig. 17 and a vehicle 1802 as shown in the block diagram 1800 of fig. 18. The vehicle (e.g., vehicle 1802 of fig. 18) produced by the vehicle manufacturing and service method 1700 of fig. 17 may include an aircraft, an airship, a rocket, a satellite, a submarine, or other vehicle as illustrative non-limiting examples. The vehicle 1802 may be manned or unmanned (e.g., an unmanned aerial vehicle or Unmanned Aerial Vehicle (UAV)).
Referring to fig. 17, a flow chart of an illustrative example of a method of pipe manufacturing and maintenance is shown and designated 1700. During pre-production, exemplary method 1700 includes specification and design of a vehicle (e.g., vehicle 1802 described with reference to fig. 18) at 1702. During the specification and design of the vehicle 1802, the method 1700 may include specifying a design of a conduit (e.g., one or more of the conduits 102A-102C of FIG. 1). At 1704, method 1700 includes material procurement. For example, the method 1700 may include purchasing material for one or more of the conduits 102A-102C of the vehicle 1802.
During production, method 1700 includes component and subassembly fabrication at 1706 and system integration of vehicle 1802 at 1708. The method 1700 may include component and subassembly manufacturing (e.g., manufacturing one or more of the conduits 102A-102C of fig. 1) and system integration (e.g., coupling one or more of the conduits 102A-102C of fig. 1 to one or more components of the vehicle 1802 (e.g., components of the ECS202 of fig. 2)) of the vehicle 1802. At 1710, the method 1700 includes authentication and delivery of the vehicle 1802, and at 1712, the vehicle 1802 is placed into service. Certification and delivery may include certification of one or more of the pipes 102A-102C of fig. 1 by inspection or non-destructive testing. During customer use, the vehicle 1802 may be scheduled for routine repair and maintenance (which may also include modification, reconfiguration, refurbishment, and so on). At 1714, the method 1700 includes performing service and maintenance on the vehicle 1802. The method 1700 may include performing repair and maintenance of the ECS202 of fig. 2 (e.g., the piping system 212 or the air conditioning unit 214) or one or more of the pipes 102A-102C of fig. 1. For example, repair and maintenance of the piping system 212 may include replacing one or more pipes of the piping system 212 with one or more of the pipes 102A-102C. As one particular non-limiting illustration, performing service and maintenance includes removing the tubes and noise attenuating silencers from the ECS202 and installing one or more of the tubes 102A-102C in the ECS202 to replace the tubes and noise attenuating silencers (e.g., zone silencers).
Each of the processes of method 1700 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For purposes of this specification, a system integrator may include, but is not limited to, any number of vehicle manufacturers and major system subcontractors; the third party may include, but is not limited to, any number of suppliers, subcontractors, and suppliers; and the operator may be an airline, leasing company, military entity, service organization, and so on.
Referring to FIG. 18, a block diagram 1800 of an illustrative example of a vehicle 1802 including a duct, such as one or more of the ducts 102A-102C of FIG. 1, is shown. For purposes of illustration, as one illustrative, non-limiting example, vehicle 1802 may include an aircraft, such as aircraft 200 of fig. 2. The vehicle 1802 may be generated by at least a portion of the method 1700 of fig. 17. As shown in fig. 18, vehicle 1802 (e.g., aircraft 200 of fig. 2) includes an airframe 1818, an interior 1822, and a plurality of systems 1820. The plurality of systems 1820 may include one or more of a propulsion system 1824, an electrical system 1826, an environmental system 1828, or a hydraulic system 1830. The plurality of systems 1820 also include an ECS 202. The ECS202 may be part of the environmental system 1828 or separate from the environmental system 1828. The ECS202 includes a first zone conduit 232, a lift conduit 234, a second zone conduit 236, and one or more of the conduits 102A-102C. The conduits 102A-102C may be manufactured by one or more steps of the method of fig. 14-16.
The apparatus and methods included herein may be used during any one or more stages of the method 1700 of fig. 17. For example, components or subassemblies corresponding to the production process 1708 may be manufactured or fabricated in a manner similar to components or subassemblies produced when the vehicle 1802 is placed into service (e.g., at 1712, but not limited thereto). Also, one or more apparatus examples, method examples, or a combination thereof may be utilized during a production stage (e.g., stage 1702-1710 of method 1700), for example, to substantially speed up assembly of the vehicle 1802 or to reduce the cost of the vehicle 1802. Similarly, one or more of the apparatus examples, method examples, or a combination thereof may be utilized during commissioning (at 1712, for example, but not limited to), repair, and maintenance (at 1714) of the vehicle 1802.
Fig. 19 is a diagram 1900 illustrating a top view of an example of an aircraft 200 including the ECS202 of fig. 2. Referring to fig. 19, aircraft 200 includes a pair of wings 1904 that are smoothly connected to a fuselage 1902. Each wing 1904 carries an engine 1906. The fuselage 1902 includes a cabin 312 for passengers and crew. In this example, aircraft 200 includes two air conditioning units 214 to provide treated air 352 (i.e., conditioned air) of fig. 3 to cabin 312 via duct system 212.
In the example shown in fig. 19, each air conditioning unit 214 has a respective ductwork 212 that extends forward and rearward along the length of the cabin 312. The piping system 212 includes the first zone pipe 232, the lifting pipe 234, and the second zone pipe 236 of fig. 2. One or more of the first zone conduits 232, the lifting conduits 234, or the second zone conduits 236 include one or more of the conduits 102A-102C. The first zone conduit 232, the lifting conduit 234, and the second zone conduit 236 may be arranged as shown in fig. 3. For example, the first zone ducts 232 receive treated air 352 from the respective air conditioning units 214 and provide the treated air 352 to the outlet port 238, e.g., via the lift ducts 234 and/or the second zone ducts 236. Although two exemplary outlet ports 238 are shown in fig. 19, the piping system 212 may include more than two outlet ports 238.
Each air conditioning unit 214 has or is coupled to at least one exhaust port 224 for conveying waste heat air from the air conditioning unit 214 overboard to the atmosphere. In one particular example, each exhaust port 224 includes a respective ram air outlet (not shown) located on an underside of a respective airfoil 102.
In the example shown in fig. 19, each air conditioning unit 214 has two air inlet ports 222 for receiving air to be processed by the duct system 212 and distributed to the cabin 312 and/or receiving waste heat air to be exhausted. In the example shown in fig. 19, each air conditioning unit 214 has an intake port 222A (e.g., a first intake port) to receive air from the atmosphere and an intake port 222B (e.g., a second intake port) to receive air from the cabin 312.
The illustrations of the examples described herein are intended to provide a general understanding of the structure of the various examples. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other examples will be apparent to those of skill in the art upon reading this disclosure. Other examples may be utilized and derived from the disclosure, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. For example, the method operations may be performed in a different order than illustrated in the figures, or one or more of the method operations may be omitted. The present disclosure and figures are, therefore, to be regarded as illustrative rather than restrictive.
Moreover, although specific examples have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar results may be substituted for the specific examples shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various examples. Combinations of the above examples, and other examples not specifically described herein, will be apparent to those of skill in the art upon reviewing the description.
The Abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing detailed description, various features may be grouped together or described in a single example for the purpose of streamlining the disclosure. The above examples illustrate but do not limit the disclosure. It should also be understood that numerous modifications and variations are possible in light of the principles of this disclosure. As the following claims reflect, the claimed subject matter may be directed to less than all of the features of any of the disclosed examples. Accordingly, the scope of the disclosure is defined by the appended claims and equivalents thereof.
Further, the present disclosure includes examples according to the following clauses:
clause 1. a conduit (102C), comprising:
a foam-filled honeycomb core structure (144) having a tubular shape; and
an air-impermeable duct wall (146) coupled to an outer surface of the foam-filled honeycomb core structure.
The duct of clause 2. the duct of clause 1, wherein the foam-filled honeycomb core structure has a structural honeycomb portion (172) comprising a metal, a composite material, or a combination thereof and defining a plurality of cavities (174).
Clause 3. the duct of clause 2, wherein the foam-filled honeycomb core structure has foam (176) in the plurality of cavities, and wherein the foam of the foam-filled honeycomb core structure comprises open-cell foam (152).
Clause 4. the pipe of clause 3, wherein the open-cell foam comprises melamine foam.
Clause 5. the conduit of any of clauses 1-4, wherein the air-impermeable conduit wall comprises a non-rigid insulating layer (116, 162, 166).
Clause 6. the duct of clause 5, further comprising a tape (622) coupled to the non-rigid insulating layer, the tape configured to constrain and seal the non-rigid insulating layer, and wherein the tape comprises Metalized Polyetheretherketone (MPEEK).
Clause 7. the conduit of any of clauses 1-6, wherein the gas-impermeable conduit wall comprises a rigid tube (166) of composite material (126).
Clause 8. the conduit of clause 7, wherein the composite material comprises a fabric material having a leno weave arrangement.
Clause 9. the duct of any of clauses 1-8, wherein the foam-filled honeycomb core structure further comprises an inlet, an outlet opposite the inlet, and an inner surface opposite the outer surface, and wherein the foam-filled honeycomb core structure is configured to absorb sound, insulate the duct, and structurally support the duct.
Clause 10. the duct of any of clauses 1-9, further comprising a rigid gas permeable tube (112, 132, 136) of composite material or a closed cell foam layer (135) coupled to an inner surface of the foam-filled honeycomb core structure.
Clause 11. a vehicle 200 comprising the conduit of any one of clauses 1-10, the vehicle comprising:
an ambient cooling system (202), the ambient cooling system comprising:
an air conditioning unit (214);
a first zone conduit (232);
a second zone conduit (234); and
a lifting pipe (236) coupled to the first zone pipe and the second zone pipe, wherein one of the first zone pipe, the second zone pipe, or the lifting pipe comprises the pipe according to clause 1.
Clause 12. the vehicle of clause 11, further comprising a fuselage including a cabin (312), wherein the first zone duct is positioned in a top (316) of the fuselage above the cabin, wherein the second zone duct is positioned below the cabin.
Clause 13. the vehicle of any of clauses 11-12, wherein the first zone duct comprises the duct, and wherein the at least one duct of the second zone duct and the at least one duct of the lifting duct comprises a second duct comprising:
a second foam-filled honeycomb core structure (144) having a tubular shape; and
a second air-impermeable duct wall (146) coupled to an outer surface of the second foam-filled honeycomb core structure.
Clause 14. the vehicle of clauses 11-12, wherein the first zone duct and the second zone duct do not include a zone muffler.
Clause 15. a method (1600) of manufacturing a pipe, the method comprising:
creating (1602) a honeycomb core structure (172) having a tubular shape, the honeycomb core structure comprising a plurality of hexagonal cavities (174);
filling (1604) a plurality of hexagonal cavities of a honeycomb core structure with foam (176) to produce a foam-filled honeycomb core structure (144); and
coupling (1606) an air-impermeable conduit wall (146) to an outer surface of the foam-filled honeycomb core structure.
Clause 16. the method of clause 15, wherein filling the plurality of hexagonal cavities of the honeycomb core structure with foam comprises depositing (1612) foam in the plurality of hexagonal cavities or generating (1614) foam within the plurality of hexagonal cavities.
Clause 17. the method of any of clauses 15-16, wherein the air-impermeable conduit wall comprises a non-rigid insulating layer (116, 162, 164, 166), and further comprising coupling (1622, 1624) a rigid perforated tube (112, 132, 136) of composite material or a closed-cell foam (134) to an inner surface of the foam-filled honeycomb core structure.
Clause 18. the method of any of clauses 15-17, wherein the air-impermeable conduit wall comprises a rigid tube of composite material (126), and further comprising coupling (1622, 1624) the rigid perforated tube of composite material (112, 132, 136) or the closed-cell foam (134) to an inner surface of the foam-filled honeycomb core structure.
Clause 19. a method (1708, 1714) of installing a duct on a vehicle, the method comprising:
installing a duct in an ambient cooling system of a vehicle, the duct comprising:
a foam-filled honeycomb core structure (144) having a tubular shape; and
an air-impermeable duct wall (146) coupled to an outer surface of the foam-filled honeycomb core structure.
Clause 20. the method of clause 19, further comprising, prior to installing the conduit of clause 1, removing (1714) the second conduit, the muffler, or a combination thereof, and wherein installing the conduit comprises replacing one or more of the second conduit, the muffler, or a combination thereof with the conduit of clause 1.
