• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    This method of manufacturing an acoustic attenuation panel made of a ceramic matrix composite material comprises the following steps: to wrap in a mold a plurality of plies consisting of fibrous reinforcements comprising fibers of a ceramic material defining a first skin (19 ) of the acoustic attenuation panel, B depositing on the first skin a plurality of blocks (21; 21a, 21b) of a first material, said fugitive material, so as to define at least one space (E) between two of said blocks , C draping on the surface formed by the blocks a plurality of plies consisting of fibrous reinforcements comprising fibers of a ceramic material so as to define a second skin (27) of the acoustic attenuation panel, D infiltrate, by means of a liquid medium, the precursor of the ceramic phase through said skins (19, 27) and in said at least one space (E) separating said blocks of fugitive material, E proceed to the elimination of n of the liquid medium by evaporation or polymerization, sintering the assembly at a temperature permitting consolidation of the ceramic material and removal of the fugitive material.
    公开号:FR3039148A1
    申请号:FR1557086
    申请日:2015-07-24
    公开日:2017-01-27
    发明作者:Arnaud Delehouze；Sylvain Sentis；Bertrand Desjoyeaux；Marc Versaevel；Frederic Fosse
    申请人:Aircelle SA；
    IPC主号:
    专利说明:

    The present invention relates to the field of acoustic panels in particular for equipping a gas ejection cone of an aircraft turbojet engine. The invention more specifically relates to a method of manufacturing an acoustic attenuation panel made of a ceramic matrix composite material, as well as an acoustic attenuation panel obtained by said method.
    As is known per se, and shown in Figure 1 attached, it is generally necessary to provide an ejection cone 1 at the rear of an aircraft turbojet engine, in part to optimize the performance of the aircraft. flow of the hot gases expelled by the turbojet, and secondly to absorb at least a portion of the noise generated by the rotation of the turbines of the turbojet and the flow of hot gases expelled.
    In this FIG. 1, the upstream and the downstream (with respect to the direction of flow of the exhaust gases of the turbojet engine) are respectively located on the left and on the right of FIG.
    This cone is intended to be positioned downstream of the turbine of the turbojet, concentrically to a shell, or "nozzle" 3, itself attached to the downstream edge of the combustion chamber of the turbojet engine.
    More specifically, the ejection cone 1 comprises, strictly speaking, a cone front portion 5 (often referred to by the Anglo-Saxon terms "front plug"), of substantially cylindrical shape, and a rear portion of the cone 7 (often referred to by the Anglo-Saxon terms "rear plug"), of conical shape.
    The front portion 5 may be especially acoustic or monolithic stiffened. In the case where the front portion 5 is acoustic, it means that it comprises at least one sandwich-type peripheral acoustic attenuation structure comprising at least one resonator operating according to the Helmhoitz principle, formed of cavities (for example nest type bee), covered with a perforated outer skin and a full inner skin.
    The outer skin is also an aerodynamic guide surface of the hot ejected gas flow (sheet) of the front portion 5 of the ejection cone.
    These two parts of the ejection cone can typically be formed by metal alloy sheets inconel 625 type or titanium B21s.
    However, in order to reduce cone mass, the use of Ceramic Matrix Composite (CMC) acoustic attenuation panels will be preferred over metallic acoustical attenuation panels. The use of these composites also makes it possible to offer a better resistance over time to panels that are permanently exposed to high temperatures.
    Document WO 2014/118216 discloses a method of manufacturing an acoustic attenuation panel made of a composite material, more particularly a ceramic matrix composite material (CMC), a material that is particularly resistant to high temperatures that may exceed 600 degrees Celsius and reach in some cases 1000 degrees Celsius; these temperatures are met in particular at the thrust cone of hot gases of the turbojet engine.
    The present invention aims to simplify and reduce the cost of manufacturing CMC panels, and relates for this purpose to a method of manufacturing a ceramic matrix composite acoustic attenuation panel comprising the following steps; A-wrap in a mold a plurality of plies consisting of fibrous reinforcements comprising fibers of a ceramic material defining a first skin of the acoustic attenuation panel, B- depositing on the first skin a plurality of blocks of a first material, said fugitive material, so as to define at least one space between two of said blocks, C-draper on the surface formed by the blocks a plurality of plies consisting of fibrous reinforcements comprising fibers of a ceramic material so as to define a second skin of the acoustic attenuation panel, D- infiltrating, by means of a liquid medium, the precursor of the ceramic phase through said skins and in said at least one space separating said blocks of fugitive material, E- proceeding with the elimination of the liquid medium by evaporation or polymerization, F- sintering the assembly, at a temperature allowing the consolidation of the ceramic oxide material and the imination of fugitive material.
    Thus, the manufacturing method according to the invention makes it possible to obtain a panel of ceramic matrix composite material in which the cellular core is manufactured at the same time as the skins and their assembly, which makes it possible to avoid the prior manufacture of the honeycomb structure, as well as its assembly with the skins of the composite panel.
    According to other optional features of the method according to the invention, taken separately or in combination: two layers of blocks of fugitive material are deposited, connected and aligned or not by means of a plurality of protuberances also of fugitive material, creating after the sintering step a septum ceramic material whose thickness is adjustable according to the acoustic need; after step B, ceramic fibers are added to the interblock space to fabricate a ceramic matrix composite septum; after step B at least one fibrous reinforcement woven or not, continuous or not ceramic material between said blocks of fugitive material - said blocks inserted in step B have various geometries and various to ensure a power sound attenuation - the corners of said blocks are rounded so as to allow connecting radii of said skins with the walls of the cellular core of the acoustic panel - said blocks of fugitive material incorporate lateral protuberances of variable dimensions, which will define the spacing between the blocks and therefore the thickness of the walls after sintering - one of the said acoustic panel skin is perforated, so as to create acoustic holes - at least one block of fugitive material comprises a plurality of protuberances in fugitive material positioned on said block so as to form, after the step of sintering the assembly, a plurality of acoustic holes in the second skin of the acoustic panel; the method comprises, before step F and preferably before step D, an additional step in which a plate is deposited having a plurality of protuberances of fugitive material positioned so that the protuberances completely traverse the reinforcing folds; fibrous of one of said skins to form, after the step of sintering the assembly, a plurality of acoustic holes; a plurality of protuberances of material capable of withstanding the sintering step, is integrated with one of the molding surfaces of the tooling, so as to form a plurality of acoustic holes in one of said skins; at least one block of fugitive material has a geometry shaped to define, after the step of sintering the assembly, at least one communication channel between the cells of the acoustic attenuation panel, allowing the drainage of liquids that can penetrate into the the panel when it is in service situation; said skins comprise a fibrous reinforcement of metal oxide and a matrix of metal oxide; at least two different ceramic materials are used for the matrix and the fibrous reinforcement of said skins. This adapts the local characteristics of the acoustic panel according to the constraints.
    The present invention also relates to an acoustic attenuation panel in a ceramic matrix composite material, which is remarkable in that it is obtained by the manufacturing process in accordance with the foregoing.
    The present invention also relates to an aircraft propulsion assembly (that is to say the assembly formed by a turbojet engine and a nacelle, this assembly possibly including the engine pylon), this propulsion unit comprising an attenuation panel. acoustic in accordance with the above. Other features and advantages of the present invention will become apparent in the light of the description which follows and the examination of the appended figures, in which: FIG. 1 represents an ejection cone as described in the preamble; 2 illustrates, in perspective, an acoustic panel obtained by means of the method according to the present invention, FIG. 3 illustrates a sectional view of this panel, during manufacture, FIG. a perspective view from above, blocks of fugitive material involved in the process according to the present invention, - Figure 5 is a perspective view of these same blocks, seen from below, - Figure 6 illustrates the matrix composite cells made of the method according to the present invention; FIG. 7 illustrates an element making it possible, alternatively, to make holes in the acoustic skin of the panel obtained in FIG. method of the present invention, and - Figure 8 illustrates a sectional view of a double-stage acoustic panel (DDOF) made by the method according to the present invention.
    Referring to Figure 2, an acoustic panel 9 obtained by the method of the present invention can be seen.
    This acoustic panel 9 comprises a plurality of cells 11 taken between a solid skin 13 and a perforated skin 15 provided with a plurality of holes 17 opening into the cells 11.
    As is known per se, the perforated skin 15 is intended to be located on the side where is the noise source that is to be attenuated, the noise penetrating through the orifices 17 inside the cells 11 and undergoing damage. the kind an attenuation (Helmhoitz's resonator).
    In the context of the present invention, the cells 11 and the two skins 13,15 are formed of ceramic matrix composite (CMC).
    As is known per se, such a material comprises a fibrous texture taken in a ceramic matrix. By way of example, the fibers forming the preform may be made of carbon, carbide or metal oxide; the ceramic forming the matrix may be carbon or silicon carbide, but most often based on alumina, these examples being of course in no way limiting.
    FIG. 3 makes it possible to understand how the method according to the present invention leads to the acoustic panel represented in FIG. 2.
    As it is indeed visible in this FIG. 3, it is first possible to drape inside a mold a plurality of plies consisting of fibrous reinforcement, comprising fibers of a ceramic material, so as to form a layer 19. -Even intended to form the full skin 13.
    This first layer 19 is then deposited with a plurality of blocks 21 of "fugitive" material, the geometry of these blocks defining complementary volumes (or "negative" volumes) defined by the cells 11; the spaces E which separate these blocks constitute the positive volumes of the walls of the alveolar soul.
    As can be seen in FIG. 3, the corners of said blocks may be rounded so as to allow connection radii of said skins with the walls of the cellular core of the acoustic panel.
    It will be noted that the fugitive material forming blocks 21 may be any material capable of disappearing during the sintering operation: it is possible in particular to use thermopiastical (polyethylene or other) or thermosetting (for example epoxy-based) materials. ) for this fugitive material, or a metal with a low melting point (for example based on lead, aluminum or tin). The elimination of the fugitive material during sintering will be at least partial, and preferably total. This elimination will be done by burning, oxidation, melting, evaporation or sublimation.
    According to a first possible variant, the blocks 21 are surmounted by pins 23 also of fugitive material defining volumes corresponding to the holes 17 of the acoustic skin 15.
    In a preferred manner, bridges 25 are made between at least some of the blocks 21, in the part of these blocks situated opposite the one where the studs 23 are located.
    These blocks 21, surmounted where appropriate their pins 23 and interconnected by the bridges 25, are particularly visible in the perspective views of Figures 4 and 5 respectively.
    Once the blocks 21 have been deposited on the first layer of ceramic material fibers 19, these blocks are covered with a second ceramic fiber layer 27 intended to form the acoustic skin 15.
    Optionally, it will be noted that it is also possible to insert fibers or any other fibrous reinforcement of ceramic material in the spaces E separating the blocks 21.
    The two layers 19, 27 and the blocks 21 thus arranged inside the mold intended to give the acoustic panel its final shape, the assembly thus produced is infiltrated by means of a medium carrying the precursor of the ceramic phase.
    According to a first variant, this media may consist of a preceramic matrix (ceramic precursor resin).
    According to a second variant, this medium may consist of a suspension containing the ceramic particles.
    This liquid medium thus impregnates the two layers 19, 27 of fibers, and is installed in the interstices defined by the spaces E between the blocks of fugitive material 21.
    This impregnation also applies to the ceramic fibers arranged in the spaces E when this option is retained.
    The media transporting the precursor of the ceramic phase is then removed by evaporation (in the case of a suspension containing the ceramic particles) or by polymerization (in the case of a ceramic precursor resin), making it possible to obtain a first consolidation of the two layers 19, 27 as well as possibly fibers disposed in the spaces E. The next step will consist of taking out the assembly thus dried of its filtration tool, then to submit it to a very high temperature rise (of the order of 1000 degrees Celsius), so as to perform the sintering of the ceramic impregnating ceramic fibers mentioned above.
    Alternatively, and if filtration tooling allows, the sintering step could be performed by leaving the dried assembly in its filtration tool.
    During this operation, the fugitive material forming the blocks 21, the pins 23 (if any) and the bridges 25 will undergo oxidation / combustion or sublimate, and escape towards the outside of the mold through the holes formed by pimples, or by specific evacuation holes located at the low point of the full skin.
    These blocks 21, these pins 23 (if any) and these bypasses 25 having disappeared, only remain their complementary volumes in the acoustic panel thus obtained, that is to say the walls 29 (Figure 6) instead of spaces E separating the fugitive blocks 21 from the holes 17 in the skin 9 in place of the pins 23 (where appropriate), and passages 31 between the cells 11 formed in the walls 29, instead of the by-passes 25.
    These passages 31 allow the drainage of liquids likely to penetrate into the cells of the acoustic panel when it is in use.
    It will be understood from the foregoing that the method according to the present invention makes it possible to obtain in an extremely simple manner a ceramic matrix composite acoustic absorption panel.
    Another possible solution for making holes 17 in acoustic skin 15 is to use a plate 33 (see FIG. 7) provided with a plurality of pins 35, these pins corresponding to holes 17.
    This plate is applied against the second fiber layer 27, before the sintering operation, and preferably before the filtration step or the polymerization step.
    According to a first option, this plate 33 can also be formed of fugitive material in which case it disappears during the sintering operation, leaving room for the holes 17.
    According to a second option, this plate may be made of a material resistant to sintering temperatures, in which case it may be part of the mold and reused for the manufacture of the following acoustic panel, and the inserts will have a demoldable form.
    It will be noted that the geometry of the blocks 21, the pins 23 and the bridges 25, can of course be adapted as needed (cylinder, parallelepiped, ...); their size is also a function of the technical specifications sought.
    It will also be noted that, according to another possible variant, the holes 17 subsequent to the sintering operation can be made by means of a suitable drilling tool.
    Referring now to FIG. 8, a sectional view of a two-stage acoustic panel (commonly referred to as "DDOF" as opposed to the "SDOF" single-stage acoustic panel presented above) can be seen.
    Such a two-stage acoustic panel comprises, in addition to the elements already presented on the subject of the single-stage panel and designated by the same references, an intermediate layer 37 often referred to as the "septum", dividing the cells 11 in the direction of their height. in two half-cells 11a, 11b, this intermediate layer 37 itself being provided with holes 39 for acoustic communication between the two half-cells 11a and 11b.
    To achieve this two-stage acoustic panel by means of the method according to the invention, one proceeds in a manner analogous to what has been described above with regard to the single-stage panel, except that it proceeds in two steps main.
    The first step consists in placing on the first layer of fibers 19 a first layer of blocks of fugitive material 21a and, where appropriate, fibers or fibrous material 27a, in a manner similar to that described with respect to the panel single storey. It should be noted that the holes 39 can be obtained by means of pins surmounting the first stage of blocks 21a, or by means of a plate 33 made of fugitive material, as represented in FIG.
    A second stage of blocks of fugitive material 21b is then superimposed on the intermediate layer 27a, the shape of these blocks corresponding, preferably, but not necessarily, to that of the blocks of the first stage 21a.
    These blocks 21b are finally covered with a second ceramic fiber layer 27b and the acoustic holes are made in this second layer 27b under the same conditions as those mentioned above for the single-stage acoustic panel.
    As described above, the assembly thus obtained is infiltrated with a liquid medium containing the precursor of the ceramic phase, the medium is removed by evaporation or polymerization, and then this assembly is subjected to sintering which makes it possible to disappearing the fugitive material blocks 21a, 21b, bridging 25 and acoustic holes made in the layers 37 and 27b of fibrous material.
    In this way, a two-stage acoustic panel is obtained, in which the acoustic waves can penetrate into the two-storey cells, through the holes 17 of the outer skin 27b, and 39 of the septum 37, thus allowing optimum acoustic attenuation.
    Optionally, the two stages of blocks 21a, 21b could be introduced in a single step, in which case they would be linked together by the pins, all of these blocks and pins being in this case produced by additive synthesis by example.
    In this solution, one could place or not fibers between these pins, and the septum would be monolithic or composite.
    Moreover, it can also be envisaged, contrary to what has been shown in FIG. 8, that the cavities defining the cells on either side of the septum 37 are not necessarily exactly opposite each other.
    Of course, the present invention is not limited to the embodiments described and shown, provided as simple examples. Thus, in particular, the concept of the present invention could be extended to an acoustic panel in which the walls 29 of the cells 11, and the full 13 and perforated skins 15 would be obtained by means of fibrous textures (fabrics, braids, knits, felts, etc.) pre-impregnated with the liquid medium containing the precursor of the ceramic phase, rather than infiltrating this medium once the fibrous textures have been placed inside the mold. Note that the plate 33 provided with its pins 35 may be applied before the filtration step (for the variant with filtration of the liquid medium through the layers of fibrous material) or polymerization (for the pre-impregnation variant of the layers of material fibrous). Thus it is also possible to use two different ceramic materials for the fibrous reinforcements but also to form said matrix, so as to obtain an acoustic panel having zones of differentiated resistances.
    权利要求:
    Claims (15)
    [1" id="c-fr-0001]
    A method of manufacturing an acoustic attenuation panel (9) of a ceramic matrix composite material comprising the steps of: draping in a mold a plurality of plies consisting of fibrous reinforcements comprising fibers of a ceramic material defining a first skin (19) of the acoustic attenuation panel, B depositing on the first skin a plurality of blocks (21; 21a, 21b) of a first material, said fugitive material, so as to define at least one space between two of said blocks, C draping on the surface formed by the blocks a plurality of plies consisting of fibrous reinforcements comprising fibers of a ceramic material so as to define a second skin (27) of the acoustic attenuation panel, D infiltrate, by means of a liquid medium, the precursor of the ceramic phase through said skins (19, 27) and in said at least one space (E) separating said blocks of fugitive material, E proceed to the elimination ion of the liquid medium by evaporation or polymerization, sintering the assembly at a temperature permitting consolidation of the oxide ceramic material and removal of the fugitive material.
    [2" id="c-fr-0002]
    2. Manufacturing method according to claim 1, characterized in that two layers of fugitive material blocks (21a, 21b) are deposited, connected and aligned or not by means of a plurality of protuberances (39) also in position. fugitive material, creating after the sintering step a septum ceramic material whose thickness is adjustable according to the acoustic need.
    [3" id="c-fr-0003]
    3. Method according to one of claims 1 or 2, characterized in that after step B, ceramic fibers are added in the interblock space to manufacture a septum (37) composite ceramic matrix.
    [4" id="c-fr-0004]
    4. Manufacturing process according to any one of claims 1 to 3, characterized in that after step B is disposed at least one fiber reinforcement woven or not, continuous or not ceramic material between said blocks of fugitive material ( 21; 21a, 21b).
    [5" id="c-fr-0005]
    5. Method according to any one of the preceding claims, wherein it is provided that the corners of said blocks (21; 21a, 21b) are rounded so as to allow connection radii of said skins with the walls of the honeycomb core of the panel. acoustic.
    [6" id="c-fr-0006]
    6. Manufacturing process according to any one of the preceding claims, characterized in that said blocks of fugitive material (21; 21a, 21b) incorporate lateral protuberances of variable dimensions, which will define the spacing between the blocks and therefore the wall thickness after sintering.
    [7" id="c-fr-0007]
    7. Manufacturing method according to any one of the preceding claims, wherein one perforates one (27) of said skins of the acoustic panel, so as to create acoustic holes (17).
    [8" id="c-fr-0008]
    8. Manufacturing process according to any one of claims 1 to 6, characterized in that at least one block of fugitive material (21; 21a, 21b) comprises a plurality of protuberances of fugitive material (23) positioned on said block so as to form, after the step of sintering the assembly, a plurality of acoustic holes (17) in the second skin (27) of the acoustic panel.
    [9" id="c-fr-0009]
    9. Manufacturing process according to any one of claims 1 to 6, characterized in that it comprises, before step F and preferably before step D, an additional step in which is deposited a plate (33) having a plurality of protuberances (35) of fugitive material positioned so that the protrusions pass integrally through the folds of fibrous reinforcements of one (27) of said skins to form, after the step of sintering the assembly, a plurality acoustic holes (17).
    [10" id="c-fr-0010]
    10. Manufacturing process according to any one of claims 1 to 6, characterized in that a plurality of protuberances of material capable of withstanding the drying or sintering step, is integrated into a molding surface of the tooling to form a plurality of acoustic holes (17) in one (27) of said skins.
    [11" id="c-fr-0011]
    11. Method according to any one of the preceding claims, characterized in that at least one block of fugitive material (21; 21a, 21b) has a geometry shaped to define, after the step of sintering the assembly, to less a communication channel between the cells of the acoustic attenuation panel, allowing drainage of liquids that can enter the panel when it is in a service situation.
    [12" id="c-fr-0012]
    12. Method according to any one of the preceding claims, characterized in that said skins (19, 27) comprise a fibrous reinforcement metal oxide and a matrix metal oxide.
    [13" id="c-fr-0013]
    13. Process according to any one of the preceding claims, characterized in that at least two different ceramic materials are used for the matrix and the fibrous reinforcements of said skins.
    [14" id="c-fr-0014]
    14. acoustic attenuation panel (9) of ceramic matrix composite material, characterized in that it is obtained by the manufacturing method according to any one of the preceding claims.
    [15" id="c-fr-0015]
    15. An aircraft propulsion assembly comprising an acoustic attenuation panel according to claim 14.
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    同族专利:
    公开号 | 公开日
    US20180230063A1|2018-08-16|
    WO2017017367A1|2017-02-02|
    FR3039148B1|2020-07-17|
    EP3325270A1|2018-05-30|
    EP3325270B1|2019-05-15|
    US10995038B2|2021-05-04|
    引用文献:
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    法律状态:
    2016-06-30| PLFP| Fee payment|Year of fee payment: 2 |
    2017-01-27| PLSC| Search report ready|Effective date: 20170127 |
    2017-06-29| PLFP| Fee payment|Year of fee payment: 3 |
    2018-03-02| CD| Change of name or company name|Owner name: SAFRAN NACELLES, FR Effective date: 20180125 |
    2018-06-28| PLFP| Fee payment|Year of fee payment: 4 |
    2019-06-21| PLFP| Fee payment|Year of fee payment: 5 |
    2020-06-23| PLFP| Fee payment|Year of fee payment: 6 |
    2021-06-23| PLFP| Fee payment|Year of fee payment: 7 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1557086|2015-07-24|
    FR1557086A|FR3039148B1|2015-07-24|2015-07-24|METHOD FOR MANUFACTURING A CERAMIC MATRIX COMPOSITE ACOUSTIC MITIGATION PANEL AND ACOUSTIC MITIGATION PANEL OBTAINED BY SAID METHOD|FR1557086A| FR3039148B1|2015-07-24|2015-07-24|METHOD FOR MANUFACTURING A CERAMIC MATRIX COMPOSITE ACOUSTIC MITIGATION PANEL AND ACOUSTIC MITIGATION PANEL OBTAINED BY SAID METHOD|
    PCT/FR2016/051934| WO2017017367A1|2015-07-24|2016-07-25|Method for producing an acoustic attenuation panel from a composite material with a ceramic oxide matrix|
    EP16760522.9A| EP3325270B1|2015-07-24|2016-07-25|Process for manufacturing an acoustic attenuation panel from a composite material with an oxide ceramic matrix|
    US15/878,432| US10995038B2|2015-07-24|2018-01-24|Method for manufacturing an acoustic attenuation panel made of an oxide ceramic-matrix composite material|
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