Structural panel with integrated coupler

An assembly is provided for an aircraft propulsion system. This assembly includes a cowl door movable between a closed position and an open position. The cowl door includes a structural panel and a mount. The structural panel includes an inner skin, an outer skin and a cellular core. The cellular core is connected to and arranged between the inner skin and the outer skin. The mount includes a base and a coupler. The base is connected to and arranged between the inner skin and the outer skin. The coupler projects out from the base.

BACKGROUND

1. Technical Field

This disclosure relates generally to structural panels and, more particularly, to removably coupling a structural panel to another body.

2. Background Information

A modern aircraft propulsion system includes a gas turbine engine housed within a nacelle. The nacelle may include cowl doors to provide access to various components configured with the gas turbine engine. Various types and configurations of cowl doors are known in the art. Furthermore, various techniques are known in the art for removably coupling those cowl doors to a fixed structure. While these known cowl doors and coupling techniques have various benefits, there is still room in the art for improvement.

There is a need in the art for improved cowl doors and cowl door coupling assemblies.

SUMMARY OF THE DISCLOSURE

According to an aspect of the present disclosure, an assembly is provided for an aircraft propulsion system. This aircraft propulsion system assembly includes a cowl door movable between a closed position and an open position. The cowl door includes a structural panel and a mount. The structural panel includes an inner skin, an outer skin and a cellular core. The cellular core is connected to and arranged between the inner skin and the outer skin. The mount includes a base and a coupler. The base is connected to and arranged between the inner skin and the outer skin. The coupler projects out from the base.

According to another aspect of the present disclosure, a cowl door is provided for an aircraft propulsion system. This cowl door includes a first skin, a second skin, a cellular core and a mount. The cellular core is between and connected to the first skin and the second skin. The mount includes a base and a coupler. The base is next to the cellular core. The base is between and connected to the first skin and the second skin. The coupler projects out from the base at an end of the cowl door. The coupler is configured to mate with a receptacle in another structure of the aircraft propulsion system.

According to still another aspect of the present disclosure, a structure is provided for an aircraft propulsion system. This aircraft propulsion system structure includes a first skin, a second skin, a cellular core and a mount. The cellular core is between and connected to the first skin and the second skin. The mount includes a base and a coupler. The base is adjacent the cellular core. The base is between the first skin and the second skin. The base is liquid interface diffusion (LID) bonded to the first skin and/or the second skin. The coupler projects out from the base at an end of the structure.

The cellular core may be bonded to the inner skin and/or the outer skin.

The cellular core may be configured as or otherwise include a honeycomb core.

The cellular core may be a first cellular core. The structural panel may also include a second cellular core connected to and arranged between the inner skin and the outer skin. The first cellular core may be arranged between and/or may be abutted against the second cellular core and the mount.

The first cellular core may have a first density. The second cellular core may have a second density that is different than (or equal to) the first density.

The structural panel may also include an inner reinforcement sheet and/or an outer reinforcement sheet. The inner reinforcement sheet may be bonded to and/or arranged between the cellular core and the inner skin. The outer reinforcement sheet may be bonded to and/or arranged between the cellular core and the outer skin.

The structural panel may be configured from or otherwise include metal.

The coupler may be configured as or otherwise include an arcuate V-blade.

The coupler may be positioned at an axial end of the cowl door. The coupler may project radially inward from the base and away from the inner skin.

A turbine engine case may be included. The turbine engine case may be configured with a receptacle. The coupler may be configured to project into and mate with the receptacle when the cowl door is in the closed position.

A seal element may be included. The seal element may be attached to the base and configured to press against the turbine engine case.

A reinforcement sheet may be included. The reinforcement sheet may be bonded to and arranged between the base and the inner skin or the outer skin.

The reinforcement sheet may be bonded to the cellular core.

The mount may be configured as a monolithic body.

The mount may be configured as or otherwise include metal.

The mount may be bonded to the inner skin and/or the outer skin.

The base may have a generally U-shaped cross-sectional geometry.

The base may include an inner flange, an outer flange and a web. The web may extend between and/or may be connected to the inner flange and the outer flange. The inner flange may be overlapped by and/or connected to the inner skin. The outer flange may be overlapped by and/or connected to the outer skin.

DETAILED DESCRIPTION

FIG.1illustrates an aircraft propulsion system20for an aircraft such as, but not limited to, a commercial airliner or a cargo plane. The propulsion system20includes a nacelle22and a gas turbine engine. This gas turbine engine may be configured as a high-bypass turbofan engine. Alternatively, the gas turbine engine may be configured as any other type of gas turbine engine capable of propelling the aircraft during flight.

The nacelle22is configured to house and provide an aerodynamic cover for the gas turbine engine. The nacelle22ofFIG.1includes a nacelle outer structure24and a nacelle inner structure26, which inner structure26may sometimes be referred to as an inner fixed structure (IFS).

Referring toFIG.2, the inner structure26covers at least an axial portion (or an entirety) of a core28of the gas turbine engine, which engine core28may include a compressor section, a combustor section and a turbine section. The inner structure26includes an inner barrel30and at least one bifurcation structure32; e.g., an upper bifurcation cowl. The inner barrel30may be a generally cylindrical/barrel-shaped cowl that extends circumferentially around and axially along the engine core28and an axial centerline34(e.g., rotational axis) of the aircraft propulsion system20. The inner barrel30at least partially forms an internal compartment36(e.g., a core compartment) within the nacelle22. This internal compartment36at least partially or completely houses the engine core28; e.g., the engine core28is arranged within the internal compartment36. The bifurcation structure32provides an aerodynamic housing for a pylon38which mounts the aircraft propulsion system20to the aircraft. The bifurcation structure32extends radially between the inner barrel30and the outer structure24.

The outer structure24covers a fan section (not shown) of the gas turbine engine. The outer structure24covers at least a forward portion of the inner structure26and its inner barrel30so as to form a bypass duct and an associated bypass flowpath40radially between the structures24and26. The outer structure24may also be configured with a thrust reverser (not shown) for redirecting airflow from the bypass flowpath40out of the nacelle22in a forward and/or outward direction. The present disclosure, however, is not limited to the foregoing exemplary general nacelle configuration.

Briefly, the bypass duct ofFIG.2is configured as an O-Duct. The term “O-duct” may describe a duct through which only a single bifurcation extends between and connects a nacelle outer structure and a nacelle inner structure. By contrast, the term “C-Duct” or “D-duct” may describe a duct through which two bifurcations (e.g., an upper bifurcation and a lower bifurcation) extend between and connect a nacelle outer structure and a nacelle inner structure. Of course, although the exemplary duct shown inFIG.2is an O-duct, the present disclosure is not limited to any particular duct configurations. In particular, the present disclosure also contemplates the nacelle22having a C-duct or a D-duct.

Referring still toFIG.2, the inner structure26may be configured with one or more movable (e.g., pivotable) inner structure components42. These inner structure components42may be configured as or otherwise include inner cowl doors44. Each of these inner cowl doors44extends circumferentially about the centerline34and the engine core28. In particular, each inner cowl door44extends circumferentially between an inner cowl upper end46and an inner cowl lower end48. The inner cowl upper end46may be pivotally connected to the bifurcation structure32and/or the pylon38by, for example, one or more hinges. Each inner cowl door44is thereby operable to move (e.g., pivot) between a closed position (position ofFIG.2) and an open position (position ofFIG.3). Referring again toFIG.2, the inner cowl lower ends48of the inner cowl doors44may be configured to latch together via one or more latches so as to at least partially or completely form the inner barrel30.

The outer structure24may be configured with one or more movable (e.g., pivotable) outer structure components50. These outer structure components50may be configured as or otherwise include outer cowl doors52. Each of these outer cowl doors52extends circumferentially about the centerline34. In particular, each outer cowl door52extends circumferentially between an outer cowl upper end54and an outer cowl lower end56. The outer cowl upper end54may be pivotally connected to the bifurcation structure32and/or the pylon38by, for example, one or more hinges. Each outer cowl door52is thereby operable to move (e.g., pivot) between a closed position (position ofFIG.2) and an open position (position ofFIG.3). Referring again toFIG.2, the outer cowl lower ends56of the outer cowl doors52may be configured to latch together via one or more latches so as to at least partially or completely form, for example, a fan cowl and/or a translatable sleeve of the outer structure24.

FIG.4illustrates an end portion of an assembly58for the aircraft propulsion system20. This aircraft propulsion system assembly58includes a fixed structure60and a moveable (e.g., pivotable) structure62such as a cowl door64. This cowl door64may be configured as one of the inner cowl doors44. Alternatively, the cowl door64may be configured as one of the outer cowl doors52, or any other moveable structure included in the aircraft propulsion system20; e.g., a fan cowl door.

The fixed structure60ofFIG.4is configured as a turbine engine case. This fixed structure60includes a tubular (or arcuate) sidewall66which extend circumferentially about (or completely around) the centerline34. The fixed structure60also includes a mount68with a receptacle70such as, but not limited to, a groove; e.g., a V-groove. This receptacle70ofFIG.4projects partially radially into the mount68. The receptacle70also extends circumferentially about the centerline34within, through or into the mount68.

The cowl door64ofFIG.4includes a structural panel72, a cowl door mount74and a seal element76; e.g., a fire seal element and/or a bulb seal element. The structural panel72includes a first (e.g., inner) skin78, a second (e.g., outer) skin80and one or more cellular cores82and84. The structural panel72ofFIG.4also includes one or more reinforcement sheets86and88.

Referring toFIGS.5and6, the first cellular core82is configured to form one or more first cavities90(e.g., radially) between the first skin78and the second skin80and, more particularly, between the first (e.g., inner) reinforcement sheet86and the second (e.g., outer) reinforcement sheet88. The first cellular core82ofFIGS.5and6, for example, is configured as a honeycomb core. This first cellular core82includes a plurality of corrugated first sidewalls92. The first sidewalls92are arranged in a side-by-side array and connected to one another such that each adjacent (neighboring) pair of first sidewalls92forms an array of the first cavities90therebetween. Referring toFIG.5, each of the first cavities90extends (e.g., generally radially) through the first cellular core82to and between the first reinforcement sheet86and the second reinforcement sheet88. Referring toFIG.6, each first cavity90may have a polygonal (e.g., hexagonal) cross-sectional geometry when viewed in a plane parallel to one or more of the elements78,80,86and/or88(seeFIG.5). The present disclosure, however, is not limited to any particular cellular core configurations. The present disclosure is also not limited to including reinforcement sheets. One or both of the reinforcement sheets86and88, for example, may be omitted such that the first cellular core82is connected directly to the first skin78and/or the second skin80.

Referring toFIGS.7and8, the second cellular core84is configured to form one or more second cavities94(e.g., radially) between the first skin78and the second skin80. The second cellular core84ofFIGS.7and8, for example, is configured as a honeycomb core. This second cellular core84includes a plurality of corrugated second sidewalls96. The second sidewalls96are arranged in a side-by-side array and connected to one another such that each adjacent (neighboring) pair of second sidewalls96forms an array of the second cavities94therebetween. Referring toFIG.7, each of the second cavities94extends (e.g., generally radially) through the second cellular core84to and between the first skin78and the second skin80. Referring toFIG.8, each second cavity94may have a polygonal (e.g., hexagonal) cross-sectional geometry when viewed in a plane parallel to one or more of the elements78and/or80(seeFIG.7). The present disclosure, however, is not limited to any particular cellular core configurations. The present disclosure is also not limited to embodiments where the second cellular core84is connected directly to the first skin78and the second skin80. For example, in other embodiments, at least one reinforcement sheet may be arranged between the second cellular core84and the first skin78and/or at least one reinforcement sheet may be arranged between the second cellular core84and the second skin80, for example, in a similar manner as described above with respect to the reinforcement sheets86and88.

The first cellular core82ofFIG.6has a first core configuration with a first density. The second cellular core84ofFIG.8has a second core configuration with a second density. Here, the term “density” may describe a ratio of material to open space in a cellular core. For example, a cellular core with a relatively low density may be configured with smaller cavities than a cellular core with a relatively high density. In the embodiments ofFIGS.6and8, the first density of the first cellular core82is different (e.g., greater) than the second density of the second cellular core84. The present disclosure, however, is not limited to such an exemplary embodiment.

Referring again toFIG.4, the first cellular core82is arranged (e.g., axially) between and may be next to, adjacent and/or abutted against the second cellular core84and the mount74. The first cellular core82is arranged (e.g., radially) between and connected to the first skin78and the second skin80. More particularly, the first cellular core82is arranged between and connected (e.g., bonded/liquid interface diffusion (LID) bonded) to the first reinforcement sheet86and the second reinforcement sheet88. The first reinforcement sheet86in turn is arranged between and connected (e.g., bonded/liquid interface diffusion (LID) bonded) to the first cellular core82and the first skin78. Similarly, the second reinforcement sheet88is arranged between and connected (e.g., bonded/liquid interface diffusion (LID) bonded) to the first cellular core82and the second skin80.

The second cellular core84is arranged (e.g., radially) between and connected (e.g., bonded/liquid interface diffusion (LID) bonded) to the first skin78and the second skin80.

Referring toFIGS.9-11, the mount74may be configured as an arcuate body; e.g., an arcuate monolithic body. The mount74ofFIG.9, for example, extends circumferentially about the centerline34. The mount74ofFIG.4extends axially along the centerline34between an interior end98and an exterior end100.

The mount74ofFIGS.4,10and11includes a base102and a coupler104. The base102ofFIGS.4,10and11includes an arcuate first (e.g., inner) flange106, an arcuate second (e.g., outer) flange108and an arcuate web110. The web110extends (e.g., radially) between and is connected to the first flange106and the second flange108. The web110may be located at (e.g., on, adjacent or proximate) the exterior end100of the mount74. The first flange106projects (e.g., axially) out from a first (e.g., inner) end112of the web110in a first direction; e.g., towards the cores82and84. The second flange108projects (e.g., axially) out from a second (e.g., outer) end114of the web110in the first direction.

The first flange106ofFIG.4is (e.g., axially and circumferentially, partially) overlapped by the first skin78. The first flange106is abutted (e.g., axially) against the first reinforcement sheet86and the first cellular core82. The first flange106is connected (e.g., bonded/liquid interface diffusion (LID) bonded) to the first skin78using, for example, LID bonding foil.

The second flange108is (e.g., axially and circumferentially, completely) overlapped by the second skin80as well as the second reinforcement sheet88. The second flange108is abutted (e.g., axially) against the first cellular core82. The second flange108is connected to the second skin80. More particularly, the second flange108is connected (e.g., bonded/liquid interface diffusion (LID) bonded) to the second reinforcement sheet88. The second reinforcement sheet88is in turn between and connected (e.g., bonded/liquid interface diffusion (LID) bonded) to the second flange108and the second skin80using, for example, LID bonding foil.

The coupler104may be configured as an arcuate member such as, but not limited to, an arcuate flange; e.g., an arcuate V-blade (see alsoFIG.13). The coupler104is position at the exterior end100of the mount74and/or a (e.g., axial) end of the cowl door64. The coupler104projects (e.g., radially inward) from the base102and its first flange106. The coupler104also projects (e.g., radially) away from the first skin78(see alsoFIG.13). With this configuration and arrangement, the coupler104is operable to project (e.g., radially) into and mate with the receptacle70. The coupler104may thereby reduce or prevent (e.g., axial) movement of the cowl door64relative to the fixed structure60when the cowl door64is in its closed position.

The seal element76is mounted to the first flange106(see alsoFIG.13). The seal element76is configured to press (e.g., radially) against the fixed structure60so as to form a sealed interface between the fixed structure60and the cowl door64.

In some embodiments, referring toFIG.12, the cowl door64may be configured without the first reinforcement sheet86and/or the second reinforcement sheet88.

In some embodiments, the cowl door64may be configured with a single cellular core; e.g., the core82or84.

In some embodiments, the cowl door64may be configured without the seal element76.

In some embodiments, one or more or each component72,74of the cowl door64ofFIGS.4and12may be constructed from or otherwise include metal such as, but not limited to, pure titanium (Ti) or titanium alloy.

In some embodiments, the base102may be configured as a solid body; e.g., without a channel defined between the flanges106and108(e.g., seeFIG.4).

In some embodiments, the cowl door64may be configured as an inner cowl door.