Casing for a Towable Sonar Apparatus and a Method of Manufacturing a Casing for a Towable Sonar Apparatus

There is provided a casing for a towable sonar apparatus, comprising:          a tubular member, wherein the tubular member comprises a foam member or a mesh member;     a first layer around the tubular member, wherein the first layer is porous.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of priority from prior United Kingdom Application number 2108892.7 filed on Jun. 21, 2021, the entire contents of which are incorporated herein by reference.

FIELD

The present disclosure relates to a casing for a towable sonar apparatus and a method of manufacturing a casing for a towable sonar apparatus.

BACKGROUND

A sonar array uses sound propagation in water for purposes such as navigation, detection of objects, mapping or communication for example. For example, sonar systems may be used for seismic arrays for oil and gas offshore surveys.

A sonar apparatus may comprise an array of acoustic sensors that generate an electrical signal in response to a received acoustic signal. In an active sonar system, the sensor components both transmit and receive acoustic signals. Acoustic transducers are an example of a component that can generate and receive acoustic signals. In a passive sonar system, the sensors only receive acoustic signals. A sonar system may be configured as a towed array sonar apparatus, in which a series of sensors are towed behind a vessel on a cable.

Movement of water around the sonar system can be a source of noise in the sonar system. For example, movement of a towed sonar apparatus through water can be a source of noise. The movement through the water creates a turbulent boundary layer around the array. This turbulent flow results in pressure fluctuations which may be detected by the acoustic sensors, resulting in noise. There is a continuing need to reduce noise in sonar systems, in order to improve sensitivity.

DETAILED DESCRIPTION

According to a first aspect, there is provided a casing for a towable sonar apparatus, comprising a tubular member, wherein the tubular member comprises a foam member or a mesh member.

In an embodiment, the casing further comprises a first layer around the tubular member, wherein the first layer is porous.

In an embodiment, the tubular member comprises a plurality of open cells. The tubular member may comprise a closed cell foam. Alternatively, the tubular member may comprise an open cell foam. Using an open cell foam provides improved performance due to the same impedance of the water outside the casing and the water inside the cells of the foam.

In an embodiment, the first layer comprises an anti-biofouling material.

In an embodiment, the first layer comprises a polymer material. The first layer may comprise low density Polyethylene (LDPE), PolyvinylChloride (PVC), Polystyrene (PS), Nylon 6 (PA6), Polycarbonate (PC) or polyurethane.

In an embodiment, the tubular member comprises a polymer material. The tubular member may comprise PolyvinylChloride (PVC) or polyurethane.

In an embodiment, the tubular member comprises an anti-biofouling material.

In an embodiment, the first layer has a thickness of less than 1 mm.

In an embodiment, the tubular member is configured to be radially contracted and expanded between a radially contracted state and a radially expanded state.

In an embodiment, the outer diameter of the tubular member in the radially expanded state is greater than 50 mm.

In an embodiment, the tubular member comprises a tapered structure at one or both ends.

According to a further aspect, there is provided a towable sonar apparatus, comprising:at least one sensor;a tube, wherein the at least one sensor is located inside the tube; andthe above described casing, wherein the casing is provided around a portion of the tube in which the at least one sensor is located.

In an embodiment, the outer diameter of the tubular member is greater than or equal to twice the outer diameter of the tube. In an embodiment, the outer diameter of the tubular member is greater than or equal to three times the outer diameter of the tube.

According to a further aspect, there is provided a vessel comprising the above described towable sonar apparatus.

According to a further aspect, there is provided a kit-of-parts comprising:a tubular member, wherein the tubular member comprises a foam member or a mesh member;a first layer, wherein the first layer is porous.

In an embodiment, the kit-of-parts further comprises a towable sonar apparatus comprising at least one sensor and a tube, wherein the at least one sensor is located inside the tube.

According to a further aspect, there is provided a computer program comprising computer executable instructions that, when executed by a processor, cause the processor to control an additive manufacturing apparatus to manufacture the above described casing or the above described kit of parts.

According to a further aspect, there is provided a method of manufacturing a device via additive manufacturing, the method comprising:obtaining an electronic file representing a geometry of a product wherein the product is the above described casing or the above described kit of parts5; andcontrolling an additive manufacturing apparatus to manufacture, over one or more additive manufacturing steps, the product according to the geometry specified in the electronic file.

According to a further aspect, there is provided a method of manufacturing a casing for a towable sonar array, the method comprising:forming a tubular member, wherein the tubular member comprises a foam member or a mesh member;forming a first layer around the tubular member, wherein the first layer is porous.

According to a further aspect, there is provided a method of manufacturing a towable sonar apparatus, comprising:manufacturing a casing for a towable sonar array according to the above described method; andlocating the casing around a portion of a tube in which at least one sensor is located.

FIG.1(a)depicts an example of a towable sonar array10, being towed by a vessel12. The array10is attached to vessel12via a towing cable14. The vessel12tows the array10in the direction of the arrow. The array10comprises a series of sensors (not shown) enclosed in a tube18. The tube18may be a PolyvinylChloride (PVC) tube or hose. The sensors generate an electrical signal in response to a received acoustic signal. The array10may also be referred to as a towed line array, a seismic streamer or a linear array.

The cable14may be several thousand metres or more in length. This allows the array10to be deployed at some distance from the vessel12, reducing the noise from the vessel12. The cable14comprises an electrical conductor along which signals generated by the sensors in the array10are coupled to a recording apparatus in the vessel12(not shown). The cable14also comprises a power line, which supplies electrical power to the components in the array10.

The array10itself may be tens or hundreds of metres in length for example. The array10may comprise multiple sections which are coupled together. An array of hundreds of metres in length may comprise multiple modules of around 10 metres in length. The modules are connected together. The connections between the modules are referred to as end connectors. The end connectors may be metallic, in order to cope with the tension that will be applied to them when the full array is towed.

The tube18may have an outer diameter of the order of 20 mm or of the order of 200 mm for example.

The array10may be an active sonar array, in which the sensor components both transmit and receive acoustic signals. Alternatively, the array may be a passive sonar array, in which the sensors only receive acoustic signals.

Various known acoustic sensors are suitable for use in a towed sonar array10of the type described in relation toFIG.1(a). The acoustic sensors may be hydrophones. A hydrophone may be based on a piezoelectric transducer. A piezoelectric transducer generates an electric potential when subjected to a pressure change. Various piezoelectric transducers can also generate acoustic signals, and therefore are suitable for use in an active sonar system. Multiple acoustic sensors are arranged spaced apart along the tube18forming an array10.

The aperture of the array10corresponds to the distance between the first and the last acoustic sensor in array. The acoustic sensors are spaced apart along the tube18, allowing directionality to be determined from the combined output. The acoustic sensors may be spaced evenly apart, with a spacing D between each sensor. One or more acoustic sensors may also be angled to allow determination of vertical depth.

A narrower beam width results in reduced noise, since noise generally originates from all directions. The gain against such noise is indicated by the directivity index. For a linear array with N hydrophones, the directivity index is given by:

where D is the spacing between the hydrophones. Increasing N increases the directivity index, and therefore improves array performance. Increasing N for a given sensor spacing D results in an increased array length.

Changes to the acoustic sensor spacing D impact the frequency of operation. Generally, the spacing may be set at half wavelength. For example, a spacing between the acoustic sensors may be of the order of 1 m for example. An array with larger N and spacing less than half wavelength could operate at a higher frequency for example.FIG.1(b)is a schematic illustration of various components of the example towable sonar array10in more detail. A first end of the towable sonar array10is attached to the cable14. The first end comprises a nose cone105, which has a tapered shape. The nose cone105may be formed from a metal material, and the tube18is attached to the nose cone105forming a smooth diameter change from the tube18to the end of the array10. Located next to the nose cone105and within the tube18is a vibration isolation module103. The vibration isolation module103is configured to suppress vibrations in the array10. The vibration isolation module103is followed by a forward interface module102, also located within the tube18. The forward interface module102may comprise various electronic components such as power regulators, analogue-to-digital converters, amplifiers and/or filters for example. The acoustic module104is then located next to the forward interface module102and within the tube18. The acoustic module102comprises the acoustic sensors as described above. Located the other side of the acoustic module102and within the tube18is an aft sensor module101. This may comprise various other sensors such as depth sensors and/or heading sensors for example. A wideband sonar module100is located at the second end of the towable array10and within the tube18. Although not shown, a second nose cone may be located at the second end of the array10. It is to be understood thatFIG.1(b)shows an example configuration, and various components shown may be omitted or modified depending on application requirements for the array10for example.

Returning toFIG.1(a), a towing winch drum16is mounted on the vessel12. The towing cable14is coupled to the winch drum16, allowing the cable14and array10to be wound in around the winch drum16when not in use. The tube18is sufficiently flexible to be wound around the winch drum16. The diameter of the tube18is also selected to be sufficiently small that the entire array10can be wound onto the winch drum16. The tube18also serves to protect the sensors contained within the tube18, for example during the reeling process. Various tubes18are known to provide sufficient protection for the enclosed sensors whilst also being sufficiently thin and flexible to be wound and stored on the reel16. For example, a PVC tube18having an outer diameter of the order of 75 mm and a wall thickness of the order of a few mm may be used.

Movement of the sonar apparatus through water can be a source of noise in the towed sonar array10. The movement through the water creates a turbulent boundary layer around the towed array10. The turbulent flow results in pressure fluctuations which may be detected by the acoustic sensors, resulting in noise. The thinner the tube18, the closer the turbulent flow layer of water is to the sensors. The smaller the diameter of the tube18, the more susceptible the array elements therefore are to flow noise, limiting overall array acoustic performance.

In order to reduce the flow noise, a larger diameter tube18may be used. However, a greater space would then need to be allotted to storage of the array on the platform. For example, for a reelable towed array, this may mean that a larger winch drum16is required. Alternatively, a shorter array10could be used. Shortening the length of the array could allow a larger diameter to be used, whilst ensuring the array still fits around a particular winch drum16. However, shortening the array limits the essential aperture, which is related to array performance as described above. To store a reelable array10takes up space on the platform, and therefore a reduction in diameter may provide additional space, or allow longer arrays to be stored on legacy winch drum16, resulting in improved array performance.

FIG.2shows a casing22for a towable sonar apparatus10in accordance with an embodiment. The figure shows a towable array10comprising a tube18located within the casing22on the right hand side of the figure. The tube18and sensors are shown separately from the casing22on the left hand side of the figure. A tubular foam member26which forms part of the casing22is also shown.FIG.3(a)shows a cross-section along the length of the array10, of a part of the array10comprising the casing22.FIG.3(b)shows a cross-section through the array, i.e. in a plane perpendicular to the length direction.

The array10may be attached to a vessel12via a towing cable14as shown inFIG.1(a), where a towing winch drum16is used to wind in the cable14and array10as described in relation toFIG.1(a). The array10comprises a series of sensors enclosed in the tube18, which may be a PVC tube or hose as described in relation toFIG.1(a). Various known sensors such as described in relation toFIG.1(a)are suitable for use in the towed sonar array10.

The casing22surrounds the tube18of the towed array. The casing22comprises a tubular foam member26, wherein the tube18is located inside the tubular foam member26. The tubular foam member26comprises a plurality of open cells. These cells are not sealed and are permeable to water. This means that when deployed, water from outside of the casing22can permeate through the open cells of the tubular foam member26. Thus when the casing22is deployed in the water, the open cells of the tubular foam member26fill with water.

The tubular foam member26is an open-cell foam sleeve. The tubular foam member26has the form of a hollow cylinder. The outer diameter of the tubular foam member26is selected based on the length of the array10and the available storage space for example. For example, the outer diameter is selected as the maximum value possible given the storage space and length of the array10for the desired application. The outer diameter may be of the order of 40 mm or 400 mm for example. The outer diameter may be around twice the outer diameter of the tube18for example. The inner diameter of the tubular foam member26is selected to fit around the tube18. As described above, the tube18may have an outer diameter of the order of 20 mm or of 200 mm for example. The tubular foam member26forms a sleeve around the outside of the tube18. The casing22may be provided over the entire acoustic aperture, i.e. the entire section of the tube18comprising the sensors.

The tubular foam element26is bonded to the outer wall of the tube18. For example, the tubular foam element26is bonded to the outer wall of the tube18by an epoxy adhesive. Various epoxy adhesives are suitable for underwater use. For example, a two part epoxy adhesive may be used.

Additionally or alternatively, the tubular foam member26is mechanically attached at one or both ends of the array10.

The tubular foam member26comprises an open cell structure foam. In an embodiment, less than 50% of the cells in the tubular foam member26are closed cells, i.e. cells that are sealed. In a further embodiment, less than 20% of the cells in the tubular foam member26are closed cells, i.e. cells that are sealed. In a further embodiment, less than 1% of the cells in the tubular foam member26are closed cells, i.e. cells that are sealed. The tubular foam member26comprises a plurality of cells which are water permeable. The foam may comprise a polymer material, for example polyurethane. The foam may comprise greater than 90% percent of void space for example.

An outer layer24is provided around the outside of the foam. The outer layer24is porous. The outer layer24is also referred to as a first layer24. The outer layer24is thin relative to the tubular foam member26. The outer layer24is also thinner than the tube18. The outer layer24provides protection to the tubular foam member26. The outer layer24is arranged around the outside of the tubular member26. The outer layer24is comprised of a water permeable material.

The outer layer24may be a sprayon coating which has been applied to the foam member26. The thickness of the outer layer24coating may be of the order of microns. The outer layer24coating comprises a polymer material having a high water permeability. Examples of such polymer materials include low density Polyethylene (LDPE), PolyvinylChloride (PVC), Polystyrene (PS), Nylon 6 (PA6) and Polycarbonate (PC). Polymer materials having a high water permeability may include polymer materials having a relatively high moisture vapour transmission rate for example.

Alternatively, the outer layer24may comprise a flexible sleeve of polymer material having holes or channels formed to allow passage of water through the sleeve and into the foam member26. For example, holes having a diameter of the order of 0.1 mm or 0.5 mm or 1 mm may be formed in the outer layer24to allow passage of water. The holes may be spaced apart around and along the outer layer24, for example at a spacing of the order of 1 cm or of the order of 5 cm. For example, the sheet may be PVC or polyurethane. The sheet may have a thickness of the order of 0.1 mm or 1 mm or 100 mm for example.

The casing22comprises the open cell structure foam member26and the water permeable outer layer24. The casing22is therefore water permeable. The tubular foam member26acts to trap a layer of relatively still water around the tube18. In other words, water permeates the open cells within the foam member26. The water permeable outer layer24further contributes to trapping a layer of relatively still water within the open cells of the foam. Water trapped within the open cells of the foam is subject to less movement than water flowing around the outside of the casing22.

The water flowing around the outside of the casing22is subject to turbulent flow. However, this turbulent flow is spaced apart from the sensors within the tube18by the thickness of the casing22. The water trapped within the casing22experiences relatively less turbulent flow. Since the turbulent flow is mainly spaced apart from the sensors by the distance of the thickness of the casing22, less noise is generated at the sensors from the turbulent flow. The casing22provides an acoustically transparent “stand-off”, which reduces the evanescent noise field at the sensor sites due to the turbulent flow. Evanescent noise results from acoustic waves that are not propagating but are spatially concentrated in the vicinity of the tube18, including the turbulent flow. The radial component of the flow noise is reduced, since the flow is spaced apart from the sensors. The turbulent boundary layer is moved away from the sensors, in other words, the separation distance increases. The casing22traps a layer of relatively still water between the towed array hose18and the turbulent flow. The casing22may be particularly suited for passive sonar arrays for example, where flow noise can have more impact due to the smaller signal size.

The casing22is collapsible. This means that when the array10is wound in around the winch drum16, the foam can be collapsed down to a smaller diameter than when it is deployed in the water. For example, the foam may be compressible to less than half the deployed outer diameter. For example, the array10including the casing22may be passed through a device that constricts the casing22prior to winding around a winch drum. The casing22is particularly suited for use with a reelable towed array. For example, by using the casing22, a reelable towed array with a longer aperture (i.e. a longer array length) can be used within a constrained volume, whilst mitigating flow noise when deployed. The casing22may therefore also be particularly suited for large aperture sonar arrays, where the longer length of the array means that a smaller diameter is required in order for the array to wind onto a winch drum of fixed size.

On reeling in, the casing22collapses as it goes onto the drum, squeezing out the water. On reeling out the sleeve expands again, trapping in relatively still water. The tubular foam member26expands when deployed and fills with water, producing a layer of relatively still water and an increased stand-off between the sensors and the flow, with a commensurate decrease in flow noise. On reeling in the tubular foam member26expels the water and compresses. Optionally, a protective element is included between layers of the array10when reeling onto the winch drum16, to prevent the weight of the array layers on top causing damage to or crushing the foam member26.

FIGS.4(a) and4(b)show cross-sectional views of the array when the tubular foam member26is collapsed.FIG.4(a)shows a cross-section along the length of the array10, of a part of the array10comprising the casing22.FIG.4(b)shows a cross-section through the array, i.e. in a plane perpendicular to the length direction. As can be seen, the thickness of the tubular foam member26is reduced, meaning that the overall outer diameter of the array10is reduced compared to the non-collapsed configuration. The casing22provides reduced flow-noise due to the thicker diameter during deployment, while providing a large aperture within a small reelable volume.

The casing22also serves to provide an extra layer of protection to the sensors. The foam is robust. The foam is resilient to shear forces, such as those experienced during reeling. The casing22is durable and therefore is not damaged by reeling in and out during deployment. The tubular foam member may be made from a resilient polymer material to enhance robustness, for example polyurethane.

The foam may deform when subject to pressure but return to its original shape once the pressure is removed. The foam has little or no hysteresis, expanding to its full extent within the deployment timescales, i.e. the time taken to reel out the array. The time may be of the order of a second to a few seconds for example. The tubular foam member26expands with a short enough hysteresis time that the stand-off is maintained before acoustic operations are performed. The hysteresis time is dependent on the foam structure and material. The foam material is manufactured or selected to be compliant in bending and not to introduce a significant bending constraint during manoeuvres.

At one or both ends of the casing22, fairings are formed to avoid instability and to provide a smooth transition for the surrounding flow. The casing22confers only a small drag increase on the towed array. The casing22provides a transition section, comprising a taper, at one or both ends of the casing22to prevent a sudden change in diameter. One or both ends of the casing22are formed with a taper.

As has been described above, a towable array may comprise multiple modules connected together with end connectors. The end connectors are also configured to allow connection of the casing22to the hose18. This may be in addition or alternative to the adhesive bonding used to fix the casing22to the hose18described above. The end connector18is increased in thickness to accommodate the casing22and fix the casing22to the hose18. The thickness increase matches the crushed diameter of the foam member26to provide smooth layering on the winch drum16.

Optionally, an anti-biofouling treatment is applied to the tubular foam member26. A sonar system may be used in the water for extended periods, for example several weeks or months. Such conditions may permit growth of marine life on the surface of the sonar system. This is referred to as ‘bio-fouling’. This may be a particular problem for sonar systems operating in tropical environments for example. Bio-fouling on the surface of the sonar system may further increase the hydrodynamic drag, and thus increase the noise and impact the sonar performance. Removal of such growth may require periodic maintenance of the array however.

By including an anti-biofouling treatment in or on the tubular foam member26, the growth of such marine life may be inhibited. The anti-biofouling treatment may comprise particles of copper or particles of a copper alloy such as brass, copper oxide, copper thiocyanate, copper bronze, copper napthenate, copper resinate, copper nickel, and copper sulfide. These particles may be mixed in with the melted polymer material used to form the foam member26. For example, a mixture of the polymer material with 10%-40% of the copper or copper alloys is used. Alternatively, the anti-fouling treatment may be applied as a spray-on coating to the foam member26.

Similarly, an anti-biofouling treatment may be included in or on the outer layer24. Particles may be mixed in with the polymer material used to form the outer layer24, for example as part of the spray coating. Alternatively, the anti-fouling treatment may be applied as a separate spray on coating after the outer layer24is applied.

FIG.5is a flow chart of a method of manufacturing a casing for a towable sonar apparatus in accordance with an embodiment, comprising a tubular foam member26.

The tubular foam member26is fabricated from an open-celled foam in S501. Manufacturing of open cells can be achieved through a chemical reaction in the foaming process causing bubbles to burst, or application of heat and pressure to burst the cell walls. A commercially available polyurethane foam may be used for example. The foam is manufactured into a tubular shape having the desired length, inner diameter and outer diameter. The foam may be machined to the tubular shape for example.

In S502, the outer layer24is formed around the tubular member26. This may comprise applying a spray on coating. Alternatively, this may comprise bonding a thin flexible sleeve around the tubular member26with an epoxy adhesive for example.

Once formed, the tubular foam member26is then bonded to the towed array. For example, the tubular foam element26is bonded to the outer wall of the tube18by an epoxy adhesive. Various epoxy adhesives are suitable for underwater use. For example, a two part epoxy adhesive may be used.

Additionally or alternatively, the tubular foam member26is mechanically attached at one or both ends of the array10.

InFIGS.2to5, a casing22is described which comprises a tubular foam member26. Alternatively however, a tubular member in the form of a mesh member may be used in place of the tubular foam member26.

In the below examples, the tubular mesh member28has a stent-like construction and comprises regular cell shapes, in periodically repeating arrangements. However alternatively and depending on the manufacturing process, the size and shape of the cells may be more random.

For example, the tubular mesh member28may alternatively be fabricated using foam based techniques. Whereas inFIGS.2to5, the tubular foam member26has an inner diameter approximately the same as the outer diameter of the hose18, the tubular mesh member28may comprise a foam tube having an inner diameter larger than the outer diameter of the hose18, such that the tubular mesh member28is spaced apart from the hose as shown inFIG.7. For example, the inner diameter of the foam tube may be around 1.5 times the outer diameter of the tube18for example, or around twice the diameter of the tube18. The thickness of the foam tube may be around 5 mm or around 10 mm or around 50 mm for example. For a reelable array10, the foam tube may then expand into the gaps between the circular hoses18on the winch drum16when stored.

FIGS.6(a),6(b) and6(c)show a schematic illustration of a tubular mesh member28, which has a stent-like construction. The tubular mesh member28forms part of a casing22for a towable sonar apparatus10in accordance with an embodiment as shown inFIGS.7and8.FIGS.6(a) and (c)show the structure of the mesh in an unwrapped configuration, whereasFIG.6(b)shows the tubular mesh member28.FIG.6(a)shows a schematic illustration of the tubular mesh member28in an expanded configuration,FIG.6(c)shows a schematic illustration of the tubular mesh member28in a collapsed configuration.

The tubular mesh member28may comprise a polymer material, such as polyurethane or PVC.

The mesh member28comprises a plurality of struts34,36defining a plurality of cells32. The cells32are the spaces enclosed by the struts34,36. The mesh28comprises vertices43connected between the struts34,36. The vertices43are the connection portions between two or more struts34,36. The vertices43are hinged portions of the mesh28.

The tubular mesh member28comprises a plurality of open cells32. These cells are not sealed and are permeable to water. This means that when deployed, water from outside of the casing22can permeate through the cells32of the tubular mesh member28. Thus when the casing22is deployed in the water, the cells32of the tubular mesh member28allow water through, such that water fills the space between the tubular mesh member28and the tube18.

The mesh28structure shown inFIG.6(a)is comprised of a plurality of ring-like struts34. Each ring-like strut34has a wave-like form, such that it comprises a plurality of peaks and troughs. The peaks and troughs of each ring-like strut34are aligned along the length of the mesh member28. The ring-like struts34are connected to each other through a plurality of longitudinal struts36. Troughs around a first ring-like strut A are connected to the corresponding troughs of a second ring-like strut B which is adjacent to the first ring-like strut A and located on one side of the first ring-like strut A. Troughs around the first ring-like strut A are also connected to the corresponding troughs of a third ring-like strut C which is adjacent to the first ring-like strut A on the other side of the first ring-like strut A.

In the collapsed configuration, shown inFIG.6(c), the waves in the ring-like struts34are compressed in the circumferential direction and elongated in the longitudinal direction. The circumference and radius of the tubular mesh member28is therefore reduced. In the expanded configuration, shown inFIG.6(a), the waves in the ring-like struts34are expanded in the circumferential direction and reduced in the longitudinal direction. The circumference and radius of the tubular mesh member28is therefore expanded.

The tubular mesh member28comprises a plurality of cells32, some of which are labelled in the figure. The cells are water permeable. The tubular mesh member28has the form of a cylinder. The outer diameter of the tubular mesh member28is selected based on the length of the array10and the available storage space. For example, the outer diameter is selected as the maximum value possible given the storage space and length of the array10for the desired application. The outer diameter may be of the order of 40 mm or 400 mm for example. The outer diameter may be around twice the outer diameter of the tube18for example.

FIGS.6(d) and (e)show an alternative structure for the mesh in an unwrapped configuration. The tubular mesh member28shown here forms part of a casing22for a towable sonar apparatus10in accordance with an embodiment as shown inFIGS.7and8.FIG.6(d)shows a schematic illustration of the tubular mesh member28in an expanded configuration andFIG.6(e)shows a collapsed configuration.

The mesh member28comprises a plurality of struts38defining a plurality of cells32. The cells32are the spaces enclosed by the struts38. The mesh28comprises vertices43connected between the struts38. The vertices43are the connection portions between two or more struts38. The vertices43are hinged portions of the mesh28.

The mesh28is comprised of a plurality of struts38arranged in a direction which has a component in the circumferential direction and a component in the longitudinal direction. The struts38are connected at each end to three other struts, forming diamond shaped cells32. At the ends of the mesh member28the struts38may be connected to one other strut38only.

The mesh28comprises rings of struts in a zig-zag formation. A first ring A comprises a plurality of struts in a zig-zag formation, such that it comprises of a plurality of peaks and troughs. The rings are connected to each other. Each trough around a first ring A is connected to a corresponding peak of a second ring C which is adjacent to the first ring A and located on one side of the first ring A. Each peak around the first ring A is connected to the corresponding trough of a third ring B which is adjacent to the first ring A on the other side of the first ring A.

In the collapsed configuration, the zig-zag formations are compressed in the circumferential direction and elongated in the longitudinal direction. The circumference and radius of the tubular mesh member28is therefore reduced. In the expanded configuration, the zig-zag formations are expanded in the circumferential direction and reduced in the longitudinal direction. The circumference and radius of the tubular mesh member28is therefore expanded.

The tubular mesh member28comprises a plurality of cells32, some of which are labelled in the figure. The cells are water permeable. The tubular mesh member28has the form of a cylinder. The outer diameter of the tubular mesh member28is selected based on the length of the array10and the available storage space. For example, the outer diameter is selected as the maximum value possible given the storage space and length of the array10for the desired application. The outer diameter may be of the order of 40 mm or 400 mm for example. The outer diameter may be around twice the outer diameter of the tube18for example.

Again, the tubular mesh member28comprises a plurality of open cells32. These cells are not sealed and are permeable to water. This means that when deployed, water from outside of the casing22can permeate through the cells32of the tubular mesh member28. Thus when the casing22is deployed in the water, the cells32of the tubular mesh member28allow water through, such that water fills the space between the tubular mesh member28and the tube18.

FIGS.7(a) and7(b)show part of a casing22for a towable sonar apparatus10in accordance with an embodiment. The figure shows a towed array10comprising a tube18located within the casing22. A tubular mesh member28such as shown inFIGS.6(a)-(c)orFIGS.6(d) and (e)forms part of the casing22.FIG.7(a)shows a cross-section along the length of the array10, of a part of the array10comprising the casing22.FIG.7(b)shows a cross-section through the array, i.e. in a plane perpendicular to the length direction.

The array10may be attached to a vessel12via a towing cable14as shown inFIG.1(a), where a towing winch drum16is used to wind in the cable14and array10as described in relation toFIG.1(a). The array10comprises a series of sensors enclosed in the tube18, which may be a PVC tube or hose as described in relation toFIG.1(a). Various known sensors such as described in relation toFIG.1(a)are suitable for use in the towed sonar array10.

The casing22surrounds the tube18of the towed array. The casing22comprises a tubular mesh element28, wherein the tube18is located inside the tubular mesh element28. The tubular mesh member28forms a sleeve around the outside of the tube18. The casing22may be provided over the entire acoustic aperture, i.e. the entire section of the towed array10comprising the sensors.

An outer layer24is provided around the outside of the tubular mesh member28. The outer layer24is porous. The outer layer24is also referred to as a first layer24. The outer layer24is a water permeable polymer. The outer layer24is thin relative to the tube18. The outer layer24provides protection to the tubular mesh member28. The outer layer24is arranged around the outside of the tubular member28. The outer layer24is a porous outer layer24.

The outer layer24may comprise a polymer material having a high water permeability. Examples of such polymer materials include low density Polyethylene (LDPE), PolyvinylChloride (PVC), Polystyrene (PS), Nylon 6 (PAS) and Polycarbonate (PC). Polymer materials having a high water permeability may include polymer materials having a relatively high moisture vapour transmission rate for example.

As described previously, the outer layer24may be a spray on coating. The thickness of the coating may be of the order of microns.

Alternatively, the outer layer24may comprise a thin flexible tube of polymer material having holes or channels formed to allow passage of water. For example, holes having a diameter of the order of 0.1 mm or 0.5 mm or 1 mm may be formed in the outer layer24to allow passage of water. The holes may be spaced apart around and along the outer layer24, for example at a spacing of the order of 1 cm. For example, the sheet may be PVC or polyurethane. The sheet may have a thickness of the order of 0.1 mm or 1 mm.

The casing22comprises the mesh member28comprising the water permeable cells and the water permeable outer layer24. The casing22is therefore water permeable. The tubular mesh member28and the outer layer24act to trap a layer of relatively still water around the tube18. In other words, water permeates the outer layer24and the cells within the mesh28. Water trapped within the casing22is subject to less movement than water flowing around the outside of the casing22.

The water flowing around the outside of the casing22is subject to turbulent flow. However, this turbulent flow is spaced apart from the sensors within the tube18by the spacing of the casing22from the tube18. The water trapped within the casing22experiences relatively less turbulent flow. Since the turbulent flow is mainly spaced apart from the sensors by the distance of the casing22, less noise is generated at the sensors from the turbulent flow. The casing22provides an acoustically transparent “stand-off”, which reduces the evanescent noise field at the sensor sites due to the turbulent flow. The casing22traps a layer of relatively still water between the towed array hose18and the turbulent flow. The casing22may be particularly suited for passive sonar arrays, for example, where flow noise can have more impact due to the smaller signal size.

The tubular mesh member28is sprung such that it deploys radially as it is reeled out, filling the gap between the mesh28and the tube18with relatively still water. The water squeezes out as the array10is reeled in again. The casing22is therefore collapsible. This means that when the array is wound in around a reel, the mesh collapses down to a smaller diameter, i.e. to a radially collapsed configuration such as was described above. For example, the array10including the casing22may be passed through a device that constricts the casing22prior to winding around a reel. The casing22is particularly suited for use with a reelable towed array. For example, by using the casing22, a reelable towed array with a longer aperture (i.e. a longer array length) can be used within a constrained volume, whilst mitigating flow noise when deployed. The casing22may be particularly suited for large aperture sonar arrays, where the longer length of the array means that a smaller diameter is required in order for the array to wind onto a winch drum of fixed size. On reeling in, the casing22collapses as it goes onto the drum, squeezing out the water. On reeling out the mesh expands again, trapping in relatively still water. The tubular mesh member28expands when deployed and fills with water producing a layer of relatively still water and an increased stand-off between the sensors and the flow, with a commensurate decrease in flow noise. On reeling in the tubular mesh member28expels the water and compresses.

FIGS.8(a) and8(b)show cross-sectional views of the array when the tubular mesh member28is collapsed.FIG.8(a)shows a cross-section along the length of the array10, of a part of the array10comprising the casing22.FIG.8(b)shows a cross-section through the array, i.e. in a plane perpendicular to the length direction. As can be seen, the outer diameter of the tubular mesh member28is reduced, meaning that the overall outer diameter of the array10is reduced compared to the non-collapsed configuration. The casing22provides reduced flow-noise due to the thicker diameter during deployment, while providing a large aperture within a small reelable volume.

The casing22also serves to provide an extra layer of protection to the sensors. The tubular mesh member28may be made from a resilient polymer material to enhance robustness, for example PVC or polyurethane.

The tubular mesh member28collapses when subject to pressure but returns to its original shape once the pressure is removed. The mesh has little or no hysteresis, expanding to its full extent within the deployment timescales, i.e. the time taken to reel out the array. The hysteresis time is dependent on the structure and material. The tubular mesh member28expands with a short enough hysteresis time that the stand-off is maintained before acoustic operations are performed.

The tubular mesh member28is manufactured to be compliant in bending and does not introduce a significant bending constraint during manoeuvres.

At one or both ends of the casing22, fairings are formed to avoid instability and to provide a smooth transition for the surrounding flow. The casing22confers only a small drag increase on the towed array. The casing22provides a transition section, comprising a taper, at one or both ends of the casing22to prevent a sudden change in diameter. One or both ends of the casing22are formed with a taper.

As has been described above, a towable array may comprise multiple modules connected together with end connectors. The end connectors are also configured to allow connection of the casing22to the hose18. This may be in addition or alternative to the adhesive bonding used to fix the casing22to the hose18described above. The end connectors may be metallic. The end connector18is increased in thickness to accommodate the casing22and fix the casing22to the hose18. The thickness increase matches the crushed diameter of the foam member26to provide smooth layering on the winch drum16.

Optionally, an anti-biofouling treatment is applied to the tubular mesh member28. By applying an anti-biofouling treatment to the mesh, the growth of marine life may be inhibited. The anti-biofouling treatment may comprise particles of copper or particles of a copper alloy such as brass, copper oxide, copper thiocyanate, copper bronze, copper napthenate, copper resinate, copper nickel, and copper sulfide. These particles are mixed in with the molten polymer material used to form the mesh member28. For example, a mixture of the polymer material with 10%-40% of the copper or copper alloys is formed. Alternatively, the anti-fouling treatment may be applied as a spray on coating to the mesh member28.

Similarly, an anti-biofouling treatment may be included in or on the outer layer24. Particles are mixed in with the polymer material used to form the outer layer24, for example as part of the spray coating. Alternatively, the anti-fouling treatment may be applied as a separate spray on coating after the outer layer24is applied.

FIG.9is a flow chart of a method of manufacturing a casing for a towable sonar apparatus in accordance with an embodiment, comprising a tubular mesh member28.

In step S901, the tubular mesh member28is constructed. The tubular mesh member28may be constructed using an additive manufacturing technique. A common example of additive manufacturing is 3D printing; however, other methods of additive manufacturing are available. Rapid prototyping or rapid manufacturing are also terms which may be used to describe additive manufacturing processes. As used herein, “additive manufacturing” refers generally to manufacturing processes wherein successive layers of material(s) are provided on each other to “build-up” layer-by-layer or “additively fabricate”, a three-dimensional component. This is compared to some subtractive manufacturing methods (such as milling or drilling), wherein material is successively removed to fabricate the part. The successive layers generally fuse together to form a monolithic component which may have a variety of integral sub-components. In particular, the manufacturing process may allow the tubular mesh member28to be integrally formed.

For example, an additive manufacturing technique based on vat polymerisation may be used to form the tubular mesh member28. In this case, a light source is used to selectively cure sequential layers of molten polymer material in a vat to form the mesh member28. Loading of particles in the resin or molten polymer, for example, anti-biofouling treatments as discussed above is possible. An example of such a technique is fusion deposition modelling. Alternatively, an additive manufacturing technique based on material extrusion may be used. In this case, a malleable polymer material (e.g. a polymer material brought to a specific temperature) is extruded and cured in sequential layers to form the mesh member28. An example of such a technique is stereolithography or digital light processing. Curing may be achieved using light, with the temperature at room temperature or slightly above.

Additive manufacturing processes may fabricate components based on three-dimensional (3D) information, for example a three-dimensional computer model (or design file), of the component. The structure of the tubular mesh member28may therefore be represented digitally in the form of a design file. Design files can take any now known or later developed file format. For example, design files may be in the Stereolithography or “Standard Tessellation Language” (.stl) format which was created for stereolithography CAD programs of 3D Systems, or the Additive Manufacturing File (.amf) format, which is an American Society of Mechanical Engineers (ASME) standard that is an extensible markup-language (XML) based format designed to allow any CAD software to describe the shape and composition of any three-dimensional object to be fabricated on any additive manufacturing printer. Further examples of design file formats include AutoCAD (.dwg) files, Blender (.blend) files, Parasolid (.x_t) files, 3D Manufacturing Format (0.3mf) files, Autodesk (3ds) files, Collada (.dae) files and Wavefront (.obj) files, although many other file formats exist. Design files can be produced using modelling (e.g. CAD modelling) software and/or through scanning the surface of tubular mesh member28to measure the surface configuration of the mesh member28.

Once obtained, a design file may be converted into a set of computer executable instructions that, once executed by a processer, cause the processor to control an additive manufacturing apparatus to produce a the tubular mesh member28according to the geometrical arrangement specified in the design file. The conversion may convert the design file into slices or layers that are to be formed sequentially by the additive manufacturing apparatus. The instructions (otherwise known as geometric code or “G-code”) may be calibrated to the specific additive manufacturing apparatus and may specify the precise location and amount of material that is to be formed at each stage in the manufacturing process. As discussed above, the formation may be through deposition or through any other suitable form of additive manufacturing method.

The code or instructions may be translated between different formats, converted into a set of data signals and transmitted, received as a set of data signals and converted to code, stored, etc., as necessary. The instructions may be an input to the additive manufacturing system and may come from a part designer, an intellectual property (IP) provider, a design company, the operator or owner of the additive manufacturing system, or from other sources. An additive manufacturing system may execute the instructions to fabricate the tubular mesh member28using any of the technologies or methods disclosed herein.

Design files or computer executable instructions may be stored in a transitory or non-transitory computer readable storage medium (e.g., memory, storage system, etc.) storing code, or computer readable instructions, representative of the tubular mesh member28to be produced. As noted, the code or computer readable instructions defining the tubular mesh member28that can be used to physically generate the tubular mesh member28, upon execution of the code or instructions by an additive manufacturing system. For example, the instructions may include a precisely defined 3D model of the tubular mesh member28and can be generated from any of a large variety of well-known computer aided design (CAD) software systems such as AutoCAD®. TurboCAD®, DesignCAD 3D Max, etc. Alternatively, a model or prototype of the tubular mesh member28may be scanned to determine the three-dimensional information of the tubular mesh member28.

Accordingly, by controlling an additive manufacturing apparatus according to the computer executable instructions, the additive manufacturing apparatus can be instructed to print out the tubular mesh member28.

In light of the above, methods of manufacture via additive manufacturing may include the steps of obtaining a design file representing the tubular mesh member28and instructing an additive manufacturing apparatus to manufacture the tubular mesh member28according to the design file. The additive manufacturing apparatus may include a processor that is configured to automatically convert the design file into computer executable instructions for controlling the manufacture of the tubular mesh member28. In these embodiments, the design file itself can automatically cause the production of the tubular mesh member28once input into the additive manufacturing device. Accordingly, in this embodiment, the design file itself may be considered computer executable instructions that cause the additive manufacturing apparatus to manufacture the tubular mesh member28. Alternatively, the design file may be converted into instructions by an external computing system, with the resulting computer executable instructions being provided to the additive manufacturing device.

Given the above, the design and manufacture of the tubular mesh member28can be realized using digital electronic circuitry, or in computer software, firmware, or hardware, or in combinations of one or more of them, as will be described in further detail below.

In S902, the outer layer24is formed around the tubular member28. This may comprise applying a spray on coating. Alternatively, this may comprise bonding a thin flexible sleeve around the tubular member28with an epoxy adhesive for example. Although this is described here as a separate step, it is to be understood that the outer layer24may alternatively be formed in the same process as the tubular mesh member28using additive manufacturing.

Once formed, the tubular mesh member28is subsequently bonded to the towed array modules. For example, the tubular mesh member28is bonded to the outer wall of the tube18by an epoxy adhesive. Various epoxy adhesives are suitable for underwater use. For example, a two part epoxy adhesive may be used. Additionally or alternatively, the tubular mesh member28is mechanically attached at one or both ends of the array10.

Although in the above examples, the tubular mesh member28or tubular foam member26is manufactured separately to the array hose18, alternatively the two parts may be manufactured in a single integrated process, using additive manufacturing for example.

Although an example in which the tubular mesh member28is manufactured using additive manufacturing techniques is described, alternative techniques may be used. For example, a laser may be used to cut away unwanted material from a polymer tube for example. In this case, material in the cell regions is cut away using a laser, leaving only the struts.

Although in the above description, the casing22is described in relation to a reelable array, the casing may be applied to various other types of towable arrays, which may be stored in various other ways on the vessel12.

In the above description, a method of manufacturing a tubular mesh member28using an additive manufacturing process was described. Other example elements described herein may additionally or alternatively be formed using an additive manufacturing process.

Suitable additive manufacturing techniques in accordance with the present disclosure include, for example, Fused Deposition Modeling (FDM), Sterolithography (SLA), or Digital Light Processing (DLP), and other known processes. The additive manufacturing processes described herein may be used for forming elements using any suitable material. For example, the material may be a polymer, a mixture of polymer and some other material (for example an anti-biofouling agent) or any other suitable material that may be in solid, liquid, powder or any other suitable form or combinations thereof. These materials are examples of materials suitable for use in additive manufacturing processes which may be suitable for the fabrication of example elements described herein. The examples described herein may be formed from any suitable mixtures of materials. For example, a component may include multiple layers, segments, or parts that are formed using different materials, processes, and/or on different additive manufacturing machines. In this manner, components may be constructed which have different materials and material properties for meeting the demands of any particular application. In addition, it should be appreciated that in alternate embodiments, all or a portion of these components may be formed via machining, and/or any other suitable manufacturing process. Indeed, any suitable combination of materials and manufacturing methods may be used to form the components described herein.

Examples described herein not only include products or components as described herein, but also methods of manufacturing such products or components via additive manufacturing and computer software, firmware or hardware for controlling the manufacture of such products via additive manufacturing.

The structure of one or more parts of the product may be represented digitally in the form of a design file. A design file, or computer aided design (CAD) file, is a configuration file that encodes one or more of the surface or volumetric configuration of the shape of a product. That is, a design file represents the geometrical arrangement or shape of the product. Design files can take any now known or later developed file format as described previously. As described above, design files can be produced using modelling (e.g. CAD modelling) software and/or through scanning the surface of a product to measure the surface configuration of the product.

As described above, once obtained, a design file may be converted into a set of computer executable instructions that, once executed by a processer, cause the processor to control an additive manufacturing apparatus to produce a product according to the geometrical arrangement specified in the design file. The code or instructions may be translated between different formats, converted into a set of data signals and transmitted, received as a set of data signals and converted to code, stored, etc., as necessary. The instructions may be an input to the additive manufacturing system and may come from a part designer, an intellectual property (IP) provider, a design company, the operator or owner of the additive manufacturing system, or from other sources. An additive manufacturing system may execute the instructions to fabricate the product using any of the technologies or methods disclosed herein.

Design files or computer executable instructions may be stored in a (transitory or non-transitory) computer readable storage medium (e.g., memory, storage system, etc.) storing code, or computer readable instructions, representative of the product to be produced. As noted, the code or computer readable instructions defining the product that can be used to physically generate the object, upon execution of the code or instructions by an additive manufacturing system. For example, the instructions may include a precisely defined 3D model of the product and can be generated from any of a large variety of well-known computer aided design (CAD) software systems such as those described above. Alternatively, a model or prototype of the component may be scanned to determine the three-dimensional information of the component.

Accordingly, by controlling an additive manufacturing apparatus according to the computer executable instructions, the additive manufacturing apparatus can be instructed to print out one or more parts of the product. These can be printed either in assembled or unassembled form. For instance, different sections of the product may be printed separately (as a kit of unassembled parts) and then subsequently assembled. Alternatively, the different parts may be printed in assembled form.

In light of the above, embodiments include methods of manufacture via additive manufacturing. This includes the steps of obtaining a design file representing the product and instructing an additive manufacturing apparatus to manufacture the product in assembled or unassembled form according to the design file. The additive manufacturing apparatus may include a processor that is configured to automatically convert the design file into computer executable instructions for controlling the manufacture of the product. In these embodiments, the design file itself can automatically cause the production of the product once input into the additive manufacturing device. Accordingly, in this embodiment, the design file itself may be considered computer executable instructions that cause the additive manufacturing apparatus to manufacture the product. Alternatively, the design file may be converted into instructions by an external computing system, with the resulting computer executable instructions being provided to the additive manufacturing device.

Although additive manufacturing technology is described herein as enabling fabrication of complex objects by building objects point-by-point, layer-by-layer, typically in a vertical direction, other methods of fabrication are possible and within the scope of the present subject matter. For example, although the discussion herein refers to the addition of material to form successive layers, one skilled in the art will appreciate that the methods and structures disclosed herein may be practiced with any additive manufacturing technique or other manufacturing technology.

Further embodiments are set out in the following clauses:

1. A casing for a towable sonar apparatus, comprising:a tubular member, wherein the tubular member comprises a foam member or a mesh member;a first layer around the tubular member, wherein the first layer is porous.

2. The casing according to clause 1, wherein the tubular member comprises a plurality of open cells.

3. The casing according to clause 1, wherein the first layer comprises an anti-biofouling material.

4. The casing according to any preceding clause, wherein the first layer comprises a polymer material.

5. The casing according to clause 4, wherein the first layer comprises low density Polyethylene (LDPE), PolyvinylChloride (PVC), Polystyrene (PS), Nylon 6 (PA6), Polycarbonate (PC) or polyurethane.

6. The casing according to any preceding clause, wherein the tubular member comprises a polymer material.

7. The casing according to clause 6, wherein the tubular member comprises PolyvinylChloride (PVC) or polyurethane.

8. The casing according to any preceding clause, wherein the tubular member comprises an anti-biofouling material.

9. The casing according to any preceding clause, wherein the first layer has a thickness of less than 1 mm.

10. The casing according to any preceding clause, wherein the tubular member is configured to be radially contracted and expanded between a radially contracted state and a radially expanded state.

11. The casing according to clause 10, wherein the outer diameter of the tubular member in the radially expanded state is greater than 50 mm.

12. The casing according to any preceding clause, wherein the tubular member comprises a tapered structure at one or both ends.

13. A towable sonar apparatus, comprising:at least one sensor;a tube, wherein the at least one sensor is located inside the tube; andthe casing of any preceding clause, wherein the casing is provided around a portion of the tube in which the at least one sensor is located.

14. A vessel comprising the towable sonar apparatus of clause 13.

15. A kit-of-parts comprising:a tubular member, wherein the tubular member comprises a foam member or a mesh member;a first layer, wherein the first layer is porous.

16. The kit-of-parts according to clause 15, further comprising a towable sonar apparatus comprising at least one sensor and a tube, wherein the at least one sensor is located inside the tube.

17. A computer program comprising computer executable instructions that, when executed by a processor, cause the processor to control an additive manufacturing apparatus to manufacture the casing of any of clauses 1 to 12 or the kit of parts according to clause 15.

18. A method of manufacturing a device via additive manufacturing, the method comprising:obtaining an electronic file representing a geometry of a product wherein the product is a casing according to any of clauses 1 to 12 or the kit of parts according to clause 15; andcontrolling an additive manufacturing apparatus to manufacture, over one or more additive manufacturing steps, the product according to the geometry specified in the electronic file.

19. A method of manufacturing a casing for a towable sonar array, the method comprising:forming a tubular member, wherein the tubular member comprises a foam member or a mesh member;forming a first layer around the tubular member, wherein the first layer is porous.

20. A method of manufacturing a towable sonar apparatus, comprising:manufacturing a casing for a towable sonar array according to the method of clause 19; andlocating the casing around a portion of a tube in which at least one sensor is located.