Abstract:
In various embodiments, a cascade array may comprise an actuator, a first cascade having a first integral flange, and a second cascade having a second integral flange, wherein the first cascade and the second cascade are operatively coupled to one another via the first integral flange and the second integral flange to form a cascade assembly, and the actuator is disposed between the first cascade and the second cascade.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. Non-Provisional patent application Ser. No. 14/681,880, entitled “RADIALLY CONNECTED CASCADE GRIDS,” filed on Apr. 8, 2015, which is a continuation-in-part of, and claims priority to, and the benefit of U.S. Non-Provisional patent application Ser. No. 14/047,224, entitled “ACTUATOR SUPPORT SYSTEM AND APPARATUS,” filed on Oct. 7, 2013, the disclosures of which are hereby incorporated by reference in their entirety. 
     
    
     FIELD 
       [0002]    The present disclosure relates to cascade-type thrust reverser systems and, more specifically, to the structural engineering of such cascade grids. 
       BACKGROUND 
       [0003]    Aircraft engines on a commercial airliner typically include a thrust reverser as part of the nacelle system. The thrust reverser system may be configured to provide reverse thrust to slow the aircraft, for example during a landing event after touchdown. One type of thrust reverser design includes cascades which help redirect the air from the fan duct in a reverse thrust direction during thrust reverser operation. The structural support for such cascades may have an impact on the external profile and/or aerodynamic features of an aircraft, possibly reducing the overall efficiency of the aircraft in flight. 
       SUMMARY 
       [0004]    In various embodiments, a thrust reverser system may comprise a first cascade, a second cascade, an actuator, and a structural connecting member. The actuator may be radially disposed between the first cascade and the second cascade. The structural connecting member may be adjacent the actuator. The structural connecting member may be configured to structurally join the first cascade and the second cascade. 
         [0005]    In various embodiments, a cascade array may comprise an actuator, a first cascade and a second cascade. The first cascade may have a first integral flange. The second cascade may have a second integral flange. The first cascade and the second cascade may be operatively coupled to one another via the first integral flange and the second integral flange to form a cascade assembly. The actuator may be disposed between the first cascade and the second cascade. 
         [0006]    In various embodiments, a thrust reverser system may comprise a first cascade, a second cascade and a first actuator. The first cascade may include a first flange. The second cascade may include a second flange. The first actuator may comprise a body. The body may include a third flange and a fourth flange. The first cascade may be operatively coupled to the first actuator by the first flange and the third flange. The second cascade may be operatively coupled to the first actuator by the second flange and the fourth flange. 
         [0007]    In various embodiments, a propulsion system may comprise a translating sleeve, a plurality of cascades, a plurality of actuators, a first track beam and a second track beam. Each cascade of the plurality of cascades may comprise a first flange and a second flange. Each of the actuators of the plurality of actuators may comprise a third flange and a forth flange. The first track beam may comprise a fifth flange. The second track beam may comprise a sixth flange. A first cascade of the plurality of cascade may be coupled to a first actuator of the plurality of actuators via the first flange and the third flange. The first cascade may be coupled to the first track beam via the second flange and the fifth flange. 
         [0008]    In various embodiments, a cascade assembly may comprise a first cascade, a second cascade and a first actuator. The first cascade may include a first flange and a second flange. The second cascade may include a third flange and a fourth flange. The first actuator may comprise a body, which may include a fifth flange and a sixth flange. The first cascade may be coupled to the second cascade through the body of the first actuator via the first flange being coupled to the firth flange and the third flange being coupled to the sixth flange. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the drawing figures, wherein like numerals denote like elements. 
           [0010]      FIG. 1  illustrates a perspective view of an aircraft, in accordance with various embodiments. 
           [0011]      FIG. 2A  illustrates a perspective view of a portion of a thrust reverser system, in accordance with various embodiments. 
           [0012]      FIG. 2B  illustrates a perspective view of cascade support structure, in accordance with various embodiments. 
           [0013]      FIG. 3A  illustrates a perspective view of a portion of a thrust reverser system, in accordance with various embodiments. 
           [0014]      FIG. 3B  illustrates a perspective view of cascade support structure, in accordance with various embodiments. 
           [0015]      FIG. 4A  illustrates a perspective cross-sectional view of a first cascade support, in accordance with various embodiments. 
           [0016]      FIG. 4B  illustrates a perspective cross-sectional view of a second cascade support, in accordance with various embodiments. 
           [0017]      FIG. 5  illustrates a perspective cross-sectional view of a splice plate cascade support, in accordance with various embodiments. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the inventions, it should be understood that other embodiments may be realized and that logical changes and adaptations in design and construction may be made in accordance with this invention and the teachings herein. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. The scope of the invention is defined by the appended claims. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. 
         [0019]    Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Surface shading lines may be used throughout the figures to denote different parts, but not necessarily to denote the same or different materials. 
         [0020]    As used herein, “aft” refers to the direction associated with the tail (e.g., the back end) of an aircraft, or generally, to the direction of exhaust of the gas turbine engine. As used herein, “forward” refers to the direction associated with the nose (e.g., the front end) of an aircraft, or generally, to the direction of flight or motion. 
         [0021]    In various embodiments, a cascade array of a thrust reverser may comprise a number of individual cascades, also sometimes called cascade grids or cascade boxes such as, for example, eight cascades per side for a total of 16 cascades per thrust reverser. The thrust reverser system may also comprise two or three actuators per side, for a total of four or six per thrust reverser. These actuators may be located between two of the cascade boxes. 
         [0022]    In various embodiments, each cascade may comprise integral flanges at their forward and aft ends that are used to structurally attach the cascade to the thrust reverser structure. The forward flanges of the cascades may be attached to forward thrust reverser fixed structure such as, for example, a torque box. The aft flanges of the cascade may be attached to a frame, such as, for example, an aft cascade ring. During reverse thrust operation, air rushes through the cascades in great volumes and at great speeds. The aerodynamic features of the cascades help turn this airflow in the desired direction for reverse thrust. The work that the cascades do on the airflow to turn it results in loads being generated in the cascades, which must be transferred back into the thrust reverser structure and ultimately to the aircraft. The torque box may be configured to take or support the fore-aft, radial, and hoop loads from the cascades. The aft cascade ring may be designed and/or configured to take or support hoop and radial loads. However, the aft cascade ring and the thrust reverser system as a whole may be designed to limit or minimize any fore-aft loads that are applied to the aft cascade ring. The loads are typically all taken by the torque box. The loads on the aft cascade ring generally impact its overall size and shape and positioning. Because of the limited space available in the area where the aft cascade ring is positioned in the thrust reverser (typically between the inner and outer panel of the translating sleeve when the thrust reverser is stowed), it can be difficult to fit an aft cascade ring that is the right size and shape to take the required loads. The space claim for the aft cascade ring structure sometimes drives the need to expand the outer shape of the thrust reverser radially outward to accommodate it. 
         [0023]    If adjacent cascade boxes can be radially attached to one another, a hoop load path is established that can allow the aft cascade ring to be advantageously reduced in size. But, in some cases part of the thrust reverser actuator assembly is positioned between adjacent cascade boxes making it difficult to structurally attach them together in the radial direction. 
         [0024]    With reference to  FIG. 1 , an aircraft  10  may comprise a fuselage  12  and a pair of wings  14 . Aircraft  10  may further comprise a propulsion system  15  (e.g., a gas turbine engine-nacelle assembly). Propulsion system  15  may be mounted to the undersides of wings  14 . Propulsion system  15  may comprise a fan and an engine core. Moreover, the engine core is configured to drive a fan to create forward thrust and/or propulsion for aircraft  10 . The engine core and fan are typically enclosed and/or housed in a nacelle. The nacelle may comprise a thrust reverser system. 
         [0025]    In various embodiments, and with reference to  FIGS. 2A and 2B , thrust reverser system  20  may be a cascade-style thrust reverser system. Thrust reverser system  20  may comprise a translating sleeve  16 , one or more actuators  22  (shown as  22 - 1 ,  22 - 2  and  22 - 3  in  FIG. 2A ), and one or more cascades  24  (shown as  24 - 1 ,  24 - 2  and  24 - 3  in  FIG. 2A ). Actuators  22  may comprise a first end and a second end. The first end may be coupled to a torque box  30 . The second end may be coupled to translating sleeve  16 . In this regard, the first end of actuator  22  is fixed to torque box  30  and the second end of actuator  22  is configured to translate forward and aft with translating sleeve  16 . In operation, actuators  22  may be extended to translate translating sleeve  16  aft to deploy and activate thrust reverser system  20 . Likewise, actuators  22  may retracted to translate translating sleeve  16  forward to return the thrust reverser system  20  to a stowed an inactive condition. 
         [0026]    In various embodiments, and with momentary reference to  FIG. 3B , these cascades may be housed between inner and outer panels of translating sleeve  16 . Translating sleeve  16  may comprise an outer panel  17  and an inner panel  18 . Outer panel  17  and inner panel  18  may be join together and may define a channel. When translating sleeve  16  is in a stowed (e.g., a forward position), cascades  24  may be housed within translating sleeve  16  in the channel defined by outer panel  17  and inner panel  18 . 
         [0027]    With reference to  FIGS. 2A-2B , one example is shown of how to structurally connect adjacent cascade boxes  24  in a radial direction while taking into account the presence of an actuator  22 . A structural connecting member is positioned or created between the adjacent cascade boxes which to transfer at least hoop loads and racking loads between them, while also allowing space for the actuator to remain in this space. In one example, actuator  22  may comprise a body or outer shell or housing  23 , which may in turn comprise one or more actuator flanges (e.g., actuator flanges  23 A and  23 B). Actuator flanges  23 A and  23 B may be an assembly that attaches to outer shell  23  or may be integrally formed as a portion of outer shell  23 . Cascades  24  may also comprise one of more cascade flanges (e.g., cascade flanges  24 A and  24 B). Cascade flanges  24 A and  24 B may be an assembly that attaches to cascade  24  or may be integrally formed as a portion of cascade  24 . Actuator flanges  23 A and  23 B may be configured to couple to and support cascade flanges  24 A and  24 B. In this regard, one or more cascades  24  may be joined and/or supported by one or more actuators  22  at actuator flanges  23 A and  23 B and cascade flanges  24 A and  24 B. The connection between the flanges (e.g., actuator flanges  23 A and  23 B and cascade flanges  24 A and  24 B) may be secured by any suitable fastener, bond, connector, and/or the like. Structurally, loads on cascade box  24 - 1  may be transferred to cascade flange  24 A, and in turn to actuator flange  23 A and outer shell  23 , and then to actuator flange  23 B, and in turn to cascade flange  24 B and cascade box  24 - 2 . These actuator and cascade flanges may run the entire length of the actuators and cascades, or they may be discreet flanges, for example a flange at the forward end and a flange at the aft end may be provided which several discreet flanges in between, according to the particular application and the need. 
         [0028]    With reference to  FIGS. 3A and 3B , one method is illustrated of establishing a radial connection between the top or bottom cascade box  24  on a thrust reverser half and the adjacent track beam (also sometimes called a hinge or latch beam). Thrust reverser system  20  may include one or more track beams  28  (e.g., track beams  28 - 1  and  28 - 2  as shown in  FIG. 3A ) extending forward to aft. Actuator  22  may also be configured to mount to track beam  28  and cascade  24 . Body  23  may comprise one or more actuator flanges (e.g., actuator flanges  23 C and  23 D). Track beam  28  may comprise one or more track beam flanges (e.g., track beam flange  28 A). Cascade  24  may comprise one or more cascade flanges (e.g., cascade flange  24 C). Track beam flange  28 A may be configured to couple to and/or be joined to actuator flange  23 D. Cascade flange  24 C may be configured to couple to and/or be joined to actuator flange  23 C. In this regard, outer shell  23  may support and/or couple cascade  24  to track beam  28 . As discussed herein, the connection between the flanges (e.g., track beam flanges  28 A and actuator flange  23 D) may be secured by any suitable fastener, bond, connector, and/or the like. Similar to the previous description, this structural attachment of a cascade box to the track beam allows for the transfer of at least racking and hoop loads through the flanges and the outer shells of the actuators. When used in combination, the two methods in  FIGS. 2B and 3B  create an array of cascade boxes  24  that are capable of transferring their hoop loads through one another to either of the track beams  28 - 1  or  28 - 2 . Because the cascade boxes have more internal load carrying capability, the size of the aft cascade ring may be reduced due to its reduced requirement for support. 
         [0029]    With reference to  FIGS. 4A-4B , other examples of structural connecting members and methods between adjacent cascade boxes  24  are illustrated. As shown in  FIG. 4A , actuator  22  may be surrounded by a two piece clamp. The two piece clamp may comprise a first clamp half  42 - 1  and a second clamp half  42 - 2 . First clamp half  42 - 1  may comprise a first flange  44 - 1  and a second flange  44 - 2 . Similarly, second clamp half  42 - 2  may comprise a third flange  44 - 3  and a fourth flange  44 - 4 . These flanges (e.g., first flange  44 - 1 , second flange  44 - 2 , third flange  44 - 3 , and/or fourth flange  44 - 4 ) may be configured to operatively couple to and/or engage cascade  24 - 1  and/or cascade  24 - 2 . 
         [0030]    First clamp half  42 - 1  and second clamp half  42 - 2  may surround actuator  22  but may not clamp to actuator  22  or even contact (in normal operation) outer shell  23 . In this regard, the two piece clamp does not engage and/or load actuator  22 . Rather, actuator  22  is separated from first clamp half  42 - 1  and second clamp half  42 - 2  by a gap  46 . Gap  46  may be any suitable size to minimize and/or eliminate contact between actuator  22  and the two piece clamp. In this arrangement, actuator  22  may float when the thrust reverser is deployed. This arrangement allows actuator  22  to take fore-aft load only when the thrust reverser is deployed and avoid potentially damaging or life-limiting side loads. This arrangement also defines a load path between first cascade  24 - 1  and second cascade  24 - 2  and through first clamp half  42 - 1  (i.e., through first flange  44 - 1 , and/or second flange  44 - 2 ) and second clamp half  42 - 2  (i.e. through third flange  44 - 3 , and/or fourth flange  44 - 4 ) to bear and/or distribute the hoop loads and radial loads across the cascade array. In this regard, the hoop loads and radial loads are isolated from the actuator, while allowing the actuator to remain in its position circumferentially spaced from and between each of the cascade boxes  24 - 1  and  24 - 2 . 
         [0031]    In various embodiments and with particular reference to  FIG. 4B , actuator  22  may be clamped by first clamp half  42 - 1  and second clamp half  42 - 2 . In this arrangement, actuator  22  may bear and translate radial, hoop and fore-aft loads through first clamp half  42 - 1  (i.e., through first flange  44 - 1 , and/or second flange  44 - 2 ) and second clamp half  42 - 2  (i.e. through third flange  44 - 3 , and/or fourth flange  44 - 4 ). This arrangement may cause the size and/or materials used to make actuator  22  and/or the body of actuator  22  to be designed to bear the loads applied to actuator  22 . 
         [0032]    In various embodiments and with reference to  FIG. 5 , first cascade  24 - 1  and second cascade  24 - 2  may comprise a first integral flange  54 - 1  and a second integral flange  54 - 2 , respectively. First integral flange  54 - 1  and second integral flange  54 - 2  may be coupled to one another with a splice plate  52 . First integral flange  54 - 1  and second integral flange  54 - 2  may be configured to pass by and at least partially surround actuator  22 . In this regard, first integral flange  54 - 1  and second integral flange  54 - 2  may create a load path between first cascade  24 - 1  and second cascade  24 - 2 , which may isolate actuator  22  from the hoop and radial loads that pass through the cascades, while allowing the actuator to remain in its position circumferentially spaced from and between each of the cascade boxes  24 - 1  and  24 - 2 . 
         [0033]    In various embodiments, typical cascade-style thrust reverser systems comprise an aft cascade ring. This aft cascade ring generally couples a plurality of cascades to one another over the radius of the cascade assembly at the aft end of the cascade assembly. The aft cascade ring may be configured to support the hoop defined by the cascade assembly. In various embodiments, this aft cascade ring may impose design limitations on the outer and/or overall envelope of the nacelle surface including, for example, the translating sleeve. In various embodiments, creating a load and support path with between actuators  22 , cascades  24 , and track beams  28  may allow the aft cascade ring to be minimized and/or removed from the thrust reverser system  20 . Moreover, in various embodiments, actuator  22  may be capable of operating with a side load applied. 
         [0034]    Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the inventions. The scope of the inventions is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. 
         [0035]    Systems, methods and apparatus are provided herein. In the detailed description herein, references to “various embodiments”, “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments. 
         [0036]    Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f) unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.