NACELLE INLET AND SYSTEM AND METHOD FOR MAKING SAME
First Claim
1. A method of manufacturing a lip-cowl for an inlet of a nacelle, the lip-cowl including a lip portion and a cowl portion and having an interior surface and an exterior surface, the method comprising:
- manufacturing a first portion of the lip-cowl using a first manufacturing technique;
positioning the first portion of the lip-cowl on a temporary support structure configured as a form; and
manufacturing a second portion of the lip-cowl using an additive manufacturing technique to deposit a material onto the form and over at least an area of the first portion of the lip-cowl positioned on the temporary support structure, wherein the material subsequently hardens so that the first and second portions of the lip-cowl are connected.
9 Assignments
0 Petitions
Accused Products
Abstract
An inlet for a nacelle and an AM system and method for manufacturing the inlet having fewer discontinuities on the exterior surface to achieve a smoother flow over the inlet. The inlet includes an annular lip-cowl and a supporting framework. The AM system includes a support structure providing a form, and AM heads for depositing materials onto the form, with the materials subsequently hardening to become the lip-cowl. The support structure may have an upright or inverted orientation, is rotatable, and may be tiltable. Components may protrude from the form to be incorporated into the lip-cowl. The AM heads are mounted on moveable arms and are computer-controlled to deposit the material onto the form, and may be moveable along a radial axis to accommodate an asymmetrical portion of the form. The AM system may further include one or more machining heads for subtractively machining the deposited material.
3 Citations
20 Claims
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1. A method of manufacturing a lip-cowl for an inlet of a nacelle, the lip-cowl including a lip portion and a cowl portion and having an interior surface and an exterior surface, the method comprising:
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manufacturing a first portion of the lip-cowl using a first manufacturing technique; positioning the first portion of the lip-cowl on a temporary support structure configured as a form; and manufacturing a second portion of the lip-cowl using an additive manufacturing technique to deposit a material onto the form and over at least an area of the first portion of the lip-cowl positioned on the temporary support structure, wherein the material subsequently hardens so that the first and second portions of the lip-cowl are connected. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method of manufacturing an annular lip-cowl for an inlet of a nacelle, the annular lip-cowl including a lip portion and a cowl portion and having an interior surface and an exterior surface, and the annular lip-cowl having no protruding fastener heads and no annularly-extending joints on the exterior surface, the method comprising:
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manufacturing a first portion of the annular lip-cowl using a first manufacturing technique; positioning the first portion of the annular lip-cowl on a temporary support structure configured as a form; and manufacturing a second portion of the annular lip-cowl using an additive manufacturing technique in which the temporary support structure is rotated about a vertical axis while one or more additive manufacturing head deposits a material onto the form and over at least an area of the first portion of the annular lip-cowl positioned on the temporary support structure, wherein the material subsequently hardens so that the first and second portions of the annular lip-cowl are connected. - View Dependent Claims (16, 17)
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18. A method of manufacturing an inlet of a nacelle, the method comprising:
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manufacturing an annular lip-cowl including a lip portion and a cowl portion and having an interior surface and an exterior surface, and the annular lip-cowl having no protruding fastener heads and no annularly-extending joints on the exterior surface, by—
manufacturing a first portion of the annular lip-cowl using a first manufacturing technique,positioning the first portion of the annular lip-cowl on a temporary support structure configured as a form, and manufacturing a second portion of the annular lip-cowl using an additive manufacturing technique in which the temporary support structure is rotated about a vertical axis while one or more additive manufacturing head deposits a material onto the form and over at least an area of the first portion of the annular lip-cowl positioned on the temporary support structure, wherein the material subsequently hardens so that the first and second portions of the annular lip-cowl are connected; manufacturing a framework configured to physically support the annular lip-cowl; and attaching the framework to the interior surface of the annular lip-cowl. - View Dependent Claims (19, 20)
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Specification