Patent ID: 12228096

DETAILED DESCRIPTION OF THE DRAWINGS

For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to a number of illustrative embodiments illustrated in the drawings and specific language will be used to describe the same.

A propulsion unit10for an aircraft according to the present disclosure includes a gas turbine engine14and an exhaust nozzle16coupled to the gas turbine engine14as shown inFIGS.1and2. The gas turbine engine14includes a fan18and an engine core20having a compressor, a combustor, and a turbine arranged axially along an axis12as shown inFIG.2. The fan18is configured to be driven by the engine core20to provide thrust for propelling an aircraft. The exhaust nozzle16is coupled to the gas turbine engine14to release an exhaust flow22from the gas turbine engine14. The exhaust system16has a variable nozzle throat area42that can be changed to optimize the exhaust flow22for low noise emissions such as, for example, during take-off and landing, or for increased engine efficiency, for example, at cruise.

The exhaust nozzle16includes a static, outer nozzle case26, a nozzle plug28, and a thrust reverser30as shownFIGS.2-7. The outer nozzle case26is fixed relative to the gas turbine engine14. The outer nozzle case26defines an outer boundary surface of the variable nozzle throat area42of the exhaust nozzle16. The nozzle plug28defines an inner boundary surface of the variable nozzle throat area42. At least a portion of the nozzle plug28is mounted for movement along the axis12to control the size and shape of the variable nozzle throat area42of the exhaust nozzle16depending on the flight configuration of the gas turbine engine or other flight conditions. The thrust reverser30is integrated into the outer nozzle case26and is configured to move relative to the outer nozzle case26and the nozzle plug28between a stored configuration as shown inFIGS.4and5, a reverse-thrust configuration as shown inFIGS.8and9, and a noise-reduction configuration, as shown inFIGS.6and7.

The outer nozzle case26is formed to extend circumferentially around the central axis12and has an outer surface50facing away from the central axis12and an opposite, inner surface52facing toward the central axis12as shown inFIGS.1and3. The inner surface52defines an interior space54radially inwardly from the inner surface52. The outer surface50partially forms an exterior surface of the exhaust nozzle14that interacts with ambient air.

The nozzle plug28is located at least partially within the interior space54and along the central axis12and cooperates with the outer nozzle case to provide the variable throat area42as shown inFIGS.1-3. The nozzle plug28is configured to interact with hot exhaust gases22flowing through the interior space54in an aft direction32to guide the hot exhaust gases22out of the interior space54through an exhaust outlet56at an aft end of the outer nozzle case26.

The thrust reverser30is coupled to the outer nozzle case26and is configured to redirect the hot exhaust gases22to provide reverse thrust in a forward direction34opposite the aft direction32when the thrust reverser30is in the reverse-thrust configuration. The thrust reverser30includes a first thrust reverser panel60coupled to the outer nozzle case26, a second thrust reverser panel62coupled to the outer nozzle case26and located on an opposite side of the outer nozzle case26from the first thrust reverser panel60, and an actuator system64coupled with the first and second thrust reverser panels60,62. The actuator system64is configured to move the first and second thrust reverser panels60,62between the stored configuration, the reverse-thrust configuration, and the noise-reduction configuration by pivoting and translating the first and second thrust reverser panels60,62relative to the outer nozzle case26.

In the stored configuration, the first and second thrust reverser panels60,62are in contact with the outer surface50of the outer nozzle case26to provide an aerodynamic profile of the exhaust nozzle16for normal flight conditions. The first and second thrust reverser panels60,62are configured to reside within respective first and second panel-receiving indentations61,63formed in the outer nozzle case26as shown inFIG.2. In this way, both of the thrust reverser panels60,62form a part of the exterior surface of the exhaust nozzle16in the stored configuration. Each panel-receiving indentation61,63extends less than 50% around the central axis12.

In the reverse-thrust configuration, the first and second thrust reverser panels60,62are spaced apart from the outer surface50of the outer nozzle case26and engage the nozzle plug28aft of the exhaust outlet56as shown inFIGS.8and9. In the reverse-thrust configuration, the first and second thrust reverser panels60,62direct at least a portion of the hot exhaust air22exiting the exhaust outlet56in the forward direction and radially outward away from the central axis12through first and second reverse thrust passageways70,72defined between the nozzle plug28and an inner surface66,68of the first and second thrust reverser panels60,62, respectively.

In the intermediate, noise-reduction configuration between the stored configuration and the reverse-thrust configuration, the first and second thrust reverser panels60,62are locked in spaced apart relation to the outer nozzle case26and the nozzle plug28. In the noise-reduction configuration, the first and second thrust reverser panels60,62direct ambient air23in the aft direction and radially inward toward the hot exhaust air22exiting the exhaust outlet56through first and second cold-air passages74,76defined between the outer surface of the outer nozzle case26and the inner surface66,68of the first and second thrust reverser panels60,62, respectively, to reduce noise produced by the hot exhaust gases22exiting the exhaust outlet56.

The first and second thrust reverser panels60,62each have outer surfaces78,80that provide a portion of the exterior surface of the exhaust nozzle16in the stored configuration. The outer surfaces78,80of the first and second thrust reverser panels60,62are flush with portions of the outer surface50of the outer nozzle case26that reside immediately adjacent to each of the thrust reverser panels60,62in the stored configuration. This provides a smooth transition between the outer surface50of the outer nozzle case26and the outer surfaces78,80of the thrust reverser panels60,62to improve aerodynamics of the propulsion unit10.

One or more portions of the actuator system64may also provide an exterior surface of the exhaust nozzle16in the stored configuration to minimize a footprint of the exhaust nozzle16while maintaining good aerodynamics. The actuator system64includes a first actuator82coupled to the first thrust reverser panel60and a second actuator84coupled to the second thrust reverser panel62. Each actuator82,84is configured to move a respective thrust reverser panel60,62between the stored configuration, the reverse-thrust configuration, and the noise reduction configuration.

The first actuator82includes a first actuator mount86fixed to the outer nozzle case26, a first plurality of panel links88coupled between the outer nozzle case26and the first thrust reverser panel60, and a first link mover90extending between the first actuator mount86and at least one link included in the first plurality of panel links88. The second actuator84includes a second actuator mount92fixed to the outer nozzle case26, a second plurality of panel links94coupled between the outer nozzle case26and the second thrust reverser panel62, and a second link mover96extending between the second actuator mount92and at least one link included in the second plurality of panel links94. In the illustrative embodiment, each actuator82,84includes two sets of actuator mounts86,92, links88,94, and link movers90,96with each respective set being mounted on diametrically opposite sides of the exhaust nozzle from one another. Each set is substantially similar, so only one set of actuator mounts86,92, links88,94, and link movers90,96is described herein.

The outer nozzle case26is formed to include actuator cavities98,100between the outer and inner surfaces50,52of the outer nozzle case as shown inFIGS.3-9. The first and second actuator mounts86,92are fixed to the outer nozzle case26and are located within a respective cavity98,100between the outer surface50of the outer nozzle case26and the inner surface52of the outer nozzle case26. In the stored configuration, the actuator mounts86,92and the link movers90,96are located entirely within a respective cavity98,100. At least a portion of one of the links88,94is configured to form a portion of the exterior surface of the exhaust nozzle16in the stored configuration.

The first and second plurality of panel links88,94each include a forward panel link88A,94A and an aft panel link88B,94B as shown inFIGS.3-9. Each forward panel link88A,94A has a first end102coupled to the outer nozzle case26and an opposite, second end104coupled to a respective one of the first and second thrust reverser panels60,62. Each aft panel link88B,94B has a first end106coupled to the outer nozzle case and an opposite, second end108coupled to the respective one of the first and second thrust reverser panels60,62. The first end106,108of each forward and aft panel link88,94remains fixed relative to the outer nozzle case26but allows rotation of the links88,94as the thrust reverser panels60,62change between the different configurations. The second end108of the aft panel links88B,94B are located aft of the second end104of each respective forward panel link88A,94A in the stored configuration, the reverse-thrust configuration, and the noise-reduction configuration.

Each forward panel link88A.94A has a first length110and each aft panel link88B,94B has a second length112less than the first length110as shown inFIG.7. The lengths110,112of the links88,94set the orientation of the first and second thrust reverser panels60,62relative to the outer nozzle case26to cause the first and second thrust reverser panels60,62to interact with the exhaust gas22and provide reverse thrust in the reverse-thrust configuration. The lengths110,112of the links88,94also set the orientation of the first and second thrust reverser panels60,62relative to the outer nozzle case26to cause the first and second thrust reverser panels60,62to interact with the ambient air23and provide reduced noise in the noise-reduction configuration. The lengths110,112of the links88,94do not change regardless of the configuration the thrust reverser panels60,62are in.

The first link mover90is coupled to the first actuator mount86for pivotable movement about a first mover pivot axis114and is coupled to the forward panel link88A of the first plurality of panel links88for pivotable movement about a second mover pivot axis116as shown inFIG.7. The second link mover96is coupled to the second actuator mount92for pivotable movement about a third mover pivot axis118and is coupled to the forward panel link94A of the second plurality of panel links94for pivotable movement about a fourth mover pivot axis120. Any suitable bearing can be used to provide the axes114,116,118,120such as a plain bearing, a roller bearing, a ball bearing, a fluid bearing, etc.

Each of the panel links88,94are also mounted to the outer nozzle case26and to each respective thrust reverser panel60,62for pivotable movement. The forward panel link88A of the first plurality of panel links88is mounted to the outer nozzle case26for pivotable movement about a first forward-link pivot axis122and is coupled to the first thrust reverser panel60for pivotable movement about a second forward-link pivot axis124. The aft panel link88B of the first plurality of panel links88is mounted to the outer nozzle case26for pivotable movement about a first aft-link pivot axis126and is coupled to the first thrust reverser panel60for pivotable movement about a second aft-link pivot axis128. In the illustrative embodiment, the second forward-link pivot axis124is aligned horizontally with the second aft-link pivot axis128.

The forward panel link94A of the second plurality of panel links94is mounted to the outer nozzle case26for pivotable movement about a third forward-link pivot axis130and is coupled to the second thrust reverser panel62for pivotable movement about a fourth forward-link pivot axis132. The aft panel link94B of the second plurality of panel links94is mounted to the outer nozzle case26for pivotable movement about a third aft-link pivot axis134and is coupled to the second thrust reverser panel62for pivotable movement about a fourth aft-link pivot axis136. In the illustrative embodiment, the third forward-link pivot axis130is aligned horizontally with the third aft-link pivot axis134.

The lengths112,114of the links88,94cause the thrust reverser panels60,62to pivot relative to the outer nozzle case in a predetermined manner. In the stored configuration, the thrust reverser panels60,62are oriented relative to the outer nozzle case26to have a first inward slope toward the central axis12. In the noise-reduction configuration, the thrust reverser panels60,62are oriented relative to the outer nozzle case26to have a second inward slope toward the central axis12, greater than the first inward slope. In the reverse-thrust configuration, the thrust reverser panels60,62are oriented relative to the outer nozzle case26to have a third inward slope toward the central axis12, greater than the first and second inward slopes.

The first and second link movers90,96each include a sheath140coupled to each respective actuator mount86,92and formed to include a piston-receiving space141and a piston142coupled to each respective forward panel link88A,94A as shown inFIG.9. The piston142is configured to extend and retract from the sheath140in the piston-receiving space141to move each respective thrust reverser panel60,62between the stored configuration, the reverse-thrust configuration, and the noise-reduction configuration. The piston142may be hydraulically actuated in the illustrative embodiment.

The first and second thrust reverser panels60,62each include a panel body144and a panel retainer146coupled to an aft end of the panel body144as shown inFIGS.10and11. The panel retainer146of the first and second thrust reverser panels60,62are configured to engage the nozzle plug28in the reverse-thrust configuration to block movement of the first and second thrust reverser panels60,62toward the stored configuration.

The nozzle plug28includes a plug body148, a first panel catch150coupled to a first side of the plug body148, and a second panel catch152coupled to an opposite second side of the plug body148as shown inFIGS.10and11. The first panel catch150is configured to engage the panel retainer146of the first thrust reverser panel60in the reverse-thrust configuration to block movement of the first thrust reverser panel60toward the stored configuration. The second panel catch152is configured to engage the panel retainer146of the second thrust reverser panel62in the reverse-thrust configuration to block movement of the second thrust reverser panel62toward the stored configuration. Once each thrust reverser panel60,62is latched to the panel catches150,152, the link movers90,96can be relaxed or deactivated such that no force is provided by the link movers90,96on the plurality of links88,94. The thrust reverse panels60,62can be held in the reverse-thrust configuration solely by the panel catches150,152.

In the illustrative embodiment shown inFIG.11, the panel catches150,152each include a horizontally-extending flange that extends in the aft direction and is spaced apart from a portion of the plug body148to provide a retainer space154radially therebetween. Each of the panel retainers146has a complementary shape to fit within the retainer space154. When latched in place, interaction between the panel retainers146and each respective panel catch150,152resists a radial force F1that extends away from the central axis12to block movement of the panel retainers146radially away from the nozzle plug28due to forces exerted on the panels60,62by the exhaust gas22.

In some embodiments, the panel catches150,152can extend inwardly toward the central axis11at an angle as shown inFIG.12. The panel retainers146can be formed to match this shape so that, interaction between the panel retainers146and each respective panel catch150,152resists the radial force F1and an axial force F2.

For supersonic speed aircrafts, government or jurisdictional regulations may limit an amount of noise produced by gas turbine engines such as during take-off and landing when aircraft are lower to ground. These noise regulations may be dependent of the weight of the aircraft and not the size of the engine. For example, a lighter aircraft that is designed to travel at supersonic speeds may need to control the noise produced by the engine14at take-off to meet the noise regulations, but also be able to increase the acceleration of exhaust products at cruise to reach supersonic speeds.

To control the noise produced by the engine14at different points of a flight cycle of the aircraft, the nozzle plug28is configured to translate axially relative to the outer nozzle case26between a slid-back take-off position as shown inFIG.15and a slid-forward cruise position as shown inFIG.14. In this way, the outer nozzle case26and the nozzle plug28together provide a reconfigurable exhaust nozzle40. The reconfigurable exhaust nozzle40adjusts the variable nozzle throat area42of the exhaust system16to control noise produced by the gas turbine engine14during operation of the gas turbine engine14at different points of the flight cycle of the aircraft10such as take-off, and landing.

When the moveable exhaust outlet44is in the slid-back take-off position, the inner surface52of the outer nozzle case and the nozzle plug28are arranged to provide a convergent nozzle shape with a maximum nozzle throat area42A as shown inFIG.15. The maximum nozzle throat area42A allows for a higher mass flow of exhaust products at a lower speed through the reconfigurable exhaust nozzle40, which results in lower noise emissions. The lower noise emissions may be helpful for meeting certain noise requirements for ground-level and low-flight level operation such as take-off and landing. As one example, the noise requirements may be related to certain zones around airports such as residential areas. An increased throat area can increase propulsion system efficiency in subsonic or transonic operation where inlet spillage or interactions with other aircraft structures would increase drag. The thrust reverse panels60,62can be deployed to the noise-reduction configuration to direct ambient air23inwardly toward the exhaust air22exiting the outlet56to further decrease noise.

When the moveable exhaust outlet44is in the slid-forward cruise position, the inner surface52of the outer nozzle case and the nozzle plug28are arranged to provide a convergent-divergent nozzle shape with a minimum nozzle throat area42B as shown inFIG.14. The minimum nozzle throat area42B allows for flow acceleration of the exhaust products and increased engine efficiency, for example, at aircraft speeds above Mach 1.0. The minimum nozzle throat area42B may cause the reconfigurable exhaust nozzle40to generate noise at greater decibel levels as compared to the maximum nozzle throat area42A. The thrust reverse panels60,62may increase drag in the noise-reduction configuration. As such, the moveable exhaust outlet40may be in the slid-forward cruise position and the thrust reverse panels60,62may be in the stored configuration at higher altitudes and/or outside of restricted noise zones.

The nozzle plug28is also axially translatable to facilitate latching of the panel retainers146with the panel catches150,152. As such, the exhaust nozzle16further includes a plug actuator170coupled with the outer nozzle case26and the movable plug body148as shown inFIGS.13-15. The plug actuator170is configured to move the movable plug body148relative to the outer nozzle case26between the slid-forward position and the slid-back position, or any position between the slid-forward position and the slid-back position.

Prior to the thrust reverse panels60,62reaching the reverse thrust configuration, the nozzle plug28may be slid slightly forward to align a retainer pocket158with a trajectory of both of the panel retainers146. Once the panel retainers146clear the panel catches150,152and extend into the retainer pockets158, the nozzle plug28can be slid aft to lock the panel retainers146in place with the panel catches150,152. The nozzle plug28can then be slid forward slightly to free the panels60,62to return to the noise-reduction configuration and the stored configuration.

The nozzle plug28further includes a stationary tailcone160, the plug body148, and a plurality of support struts162as shown inFIGS.13-15. The stationary tailcone160is located within the interior space54upstream of the exhaust outlet56. The plug body148extends in the aft direction away from the stationary tailcone along the central axis and is movable relative to the stationary tailcone160. The plurality of support struts162are coupled to the movable plug body148and spaced circumferentially apart from one another around the central axis12to support the movable plug body148along the central axis12. Each of the plurality of struts162extends inwardly toward the central axis12and aft away from the actuator170.

The movable plug body148includes a plug tail164having a variable-diameter, a plug stem166coupled with a forward end of the plug tail and having a substantially constant diameter, and a plug guide168fixed to the plug stem166for movement therewith. The plug guide168is configured to engage the stationary tailcone160to block rotation of the movable plug body148relative to the stationary tailcone160about the central axis12.

The stationary tailcone160is formed to include a stem-receiving space161located along the central axis12as shown inFIGS.14and15. The plug stem166extends into the stem-receiving space161of the stationary tailcone160. The movable plug body148is simply supported by both the stationary tailcone160and the plurality of support struts162. The plug stem166extends into the stem-receiving space161in both the slid-forward position and the slid-back position.

The plug guide168includes a plurality of rollers169spaced circumferentially around the central axis from one another and protruding radially outward from an outer surface of the plug stem166to engage with an interior surface defining the stem-receiving space161as shown inFIGS.16and17. The stem-receiving space161includes a plurality of guide slots163spaced circumferentially apart from one another. Each roller169included in the plurality of rollers169is configured to extend into a respective guide slot163included in the plurality of guide slots163. Each of the rollers169is configured to rotate about a roller axis169A that extends through the central axis12and is perpendicular to the central axis12. The rollers169are configured to travel through the slots163and rotate about each respective axis169A as the plug actuator170moves the movable plug body148between the slid-forward position and the slid-back position.

The plug actuator170includes an actuator ring172coupled to each of the support struts162, an actuator piston174coupled to the actuator ring172and the outer nozzle case26, and a plurality of ring guides176coupled to the actuator ring172as shown inFIGS.14,15, and18. The actuator ring172extends annularly around the central axis12. The actuator piston174is configured to translate the actuator ring172forward and aft to move the plug body148and the plurality of support struts162between the slid-forward position and the slid-back position. The plurality of ring guides176are configured to guide movement of the actuator ring172relative to the outer nozzle case26and block rotation of the actuator ring172and the plurality of support struts162about the central axis12.

The plurality of ring guides176includes a plurality of rollers177that engage the outer nozzle case26and roll along the outer nozzle case26as the actuator piston174moves the actuator ring172forward and aft. The outer nozzle case26is formed to include a ring cavity178. The actuator ring172is at least partially received in the ring cavity178when the plug body148is in the slid-forward position. The actuator ring172extends from the ring cavity178to form a portion of an outer exhaust gas boundary with the inner surface52of the outer nozzle case26when the plug body148is in the slid-back position.

The outer nozzle case26is formed to include a plurality of slots that open radially inward into the ring cavity178. Each of the rollers177is received in a respective slot included in the plurality of slots180. Each of the struts included in the plurality of struts162is aligned circumferentially with at least one slot included in the plurality of slots180. The plurality of rollers177includes a plurality of forward rollers and a plurality of aft rollers spaced apart from the plurality of forward rollers. Each of the struts included in the plurality of struts162is aligned circumferentially with at least one roller included in the plurality of rollers177. Each of the rollers177is configured to rotate about a roller axis177A that extends through the central axis12and that is perpendicular to the central axis12.

The plug stem166has a first diameter182as shown inFIG.18. The plug tail164has a second diameter184, greater than the first diameter182, at a first end of the plug tail164closest to the plug stem166. The plug tail164has a third diameter186, less than the first diameter182and the second diameter184, at a second end of the plug tail164furthest from the plug stem166. The plug tail164has a fourth diameter188, greater than the first, second, and third diameters182,184,186, axially between the first end and the second end of the plug tail164.

The exhaust nozzle16is manufactured and installed on the gas turbine engine14according to a process1000as shown inFIG.19. The process1000includes a step1002of forming the outer nozzle case26. The outer nozzle case26can be formed in any shape or size, but the shape and size of the outer nozzle case26is used in subsequent steps of the process1000to form the thrust reverser30. Forming the outer nozzle case26includes forming the first panel receiving indentation61into the outer surface50of the outer nozzle case26and forming the second panel-receiving indentation63into the outer surface50of the outer nozzle case26.

The process1000further includes a step1004of forming the nozzle plug28. The nozzle plug28can be formed in any shape or size, but the shape and size of the nozzle plug is used in subsequent steps of the process1000to form the thrust reverser. In some embodiments, the step1004of forming the nozzle plug28includes determining engine performance characteristics of the gas turbine engine14and sizing the nozzle plug28relative to the outer nozzle case26so that the exhaust nozzle16meets those engine performance characteristics.

The step1004of forming the nozzle plug28includes forming the stationary tailcone160and inserting the movable plug body148into the space161formed in an aft end of the stationary tailcone160. In this way, the movable plug body148is translatable relative to the stationary tailcone160and the outer nozzle case26along the central axis12during use between the slid-back configuration and the slid-forward configuration.

The process1000further includes a step1006of attaching the nozzle plug28to at least one of the gas turbine engine14and the outer nozzle case26to reside within the interior space54and along the central axis12. The step1006of attaching the nozzle plug28may include attaching the nozzle plug28, or a portion thereof, to an aft end of the gas turbine engine14via the stationary tailcone160and/or to the outer nozzle case26via the plurality of support struts162.

The process1000may further include a step1008of forming the thrust reverser30. The thrust reverser30is formed with dimensions that allow the first thrust reverser panel60and the second thrust reverser panel62to change between the stored configuration, the reverse thrust configuration, and the noise-reduction configuration. The step1008may include sizing the outer nozzle case26, the nozzle plug28, or portions thereof to fit the thrust reverser30. The step1008may include sizing and/or shaping the thrust reverse panels60,62based on one or more performance criteria (i.e. a performance curve) of the gas turbine engine14. The actuator system64may also be sized or shaped relative to the outer nozzle case26, the nozzle plug28and the thrust reverse panels60,62to ensure the panels60,62are properly oriented in each configuration.

Once the thrust reverser30is formed, the process1000further includes a step1010of attaching the thrust reverser30to the outer nozzle case26. The step1010includes of attaching the first and second thrust reverser panels60,62to the outer nozzle case26includes placing the first thrust reverser panel in the first panel-receiving indentation61and placing the second thrust reverser panel in the second panel-receiving indentation63. When the panels60,62are received in the indentations61,63, the outer surface of both the first and second thrust reverser panels60,62cooperate with the outer surface of the outer nozzle case to provide the exterior surface of the exhaust nozzle. The steps1002and1008of forming the outer nozzle case26and the thrust reverser30include sizing the outer nozzle case26and the thrust reverser30so that this is possible.

The step1008of forming the thrust reverser30includes forming the forward panel links88A,94A and the aft panel links88B,94B. The step1010includes attaching each of the panel links88,94to the outer nozzle case26and to the first and second thrust reverser panels60,62by bearings so that each panel link rotates about a respective pair of axes122,124,126,128,130,132,134,136when moved by the actuator system64from the stored configuration to the reverse thrust configuration. The step1010further includes attaching the first link mover90to the outer nozzle case26and the first forward panel link88A and attaching the second link mover96to the outer nozzle case26and the second forward panel link94A via bearings to allow each link mover to rotate about a pair of axes114,116,118,120as the link movers move from a retracted position to an extended position.

The step1010may further include sizing the first and second forward panel links88A,94A to have the first length110and sizing the first and second aft panel links88B,94B to have the second length112that is less than the first length110. These dimensions cause the first and second thrust reverser panels60,62to gradually increase inward slope toward the central axis as the first and second thrust reverser panels60,62move from the stored configuration to the reverse-thrust configuration. The step1010further includes attaching a fixed end of the first forward and aft panel links88A,88B along an axial line extending parallel to the central axis12.

The step1008may further include forming the inner surface66,68of the first and second thrust reverser panels60,62to have a convex shape relative to the central axis12. The step1002of forming the outer nozzle case26may include forming a portion of the outer surface50of the outer nozzle case26defining the first and second panel-receiving indentations61,63to have a concave shape that matches the convex shape of the first and second thrust reverser panels60,62. The step1002of forming the outer nozzle case includes forming the inner surface52of the outer nozzle case26to have a convex shape.

The step1010may further include aligning a portion of the actuator system64with the exterior surface of the exhaust nozzle such that the portion of the actuator system64cooperates with the outer nozzle case26and the first and second thrust reverser panels60,62to define the exterior surface.

The step1002may further include forming the actuator cavities98,100in the outer nozzle case and between the inner surface52and the outer surface50of the outer nozzle case. The step1010of attaching the thrust reverser30to the outer nozzle case26includes placing the first and second forward and aft panel links88,94at least partially in the actuator cavities98,100.

While the disclosure has been illustrated and described in detail in the foregoing drawings and description, the same is to be considered as exemplary and not restrictive in character, it being understood that only illustrative embodiments thereof have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected.