Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
  • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
  • B29C39/026—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles characterised by the shape of the surface
• • G—PHYSICS
  • G10—MUSICAL INSTRUMENTS; ACOUSTICS
  • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
  • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
  • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
  • G10K11/162—Selection of materials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C33/00—Moulds or cores; Details thereof or accessories therefor
  • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
  • B29C33/3842—Manufacturing moulds, e.g. shaping the mould surface by machining
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C33/00—Moulds or cores; Details thereof or accessories therefor
  • B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
  • B29C33/52—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles soluble or fusible
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
  • B29C39/22—Component parts, details or accessories; Auxiliary operations
  • B29C39/26—Moulds or cores
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
  • B29C39/22—Component parts, details or accessories; Auxiliary operations
  • B29C39/36—Removing moulded articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y10/00—Processes of additive manufacturing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y80/00—Products made by additive manufacturing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B29C64/10—Processes of additive manufacturing
  • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
  • B29K2105/16—Fillers
  • B29K2105/162—Nanoparticles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2821/00—Use of unspecified rubbers as mould material
  • B29K2821/003—Thermoplastic elastomers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2821/00—Use of unspecified rubbers as mould material
  • B29K2821/006—Thermosetting elastomers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2829/00—Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof, as mould material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2831/00—Use of polyvinylesters or derivatives thereof as mould material
  • B29K2831/04—Polymers of vinyl acetate, e.g. PVAc, i.e. polyvinyl acetate
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2867/00—Use of polyesters or derivatives thereof as mould material
  • B29K2867/04—Polyesters derived from hydroxycarboxylic acids
  • B29K2867/046—PLA, i.e., polyactic acid or polyactide
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
  • B29K2995/0037—Other properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/757—Moulds, cores, dies
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
  • F02C7/00—Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
  • F02C7/24—Heat or noise insulation
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2250/00—Geometry
  • F05D2250/20—Three-dimensional
  • F05D2250/28—Three-dimensional patterned
  • F05D2250/283—Three-dimensional patterned honeycomb
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2260/00—Function
  • F05D2260/96—Preventing, counteracting or reducing vibration or noise
  • F05D2260/963—Preventing, counteracting or reducing vibration or noise by Helmholtz resonators

Definitions

• the present invention relates to the field of acoustic meta-materials, as well as that of their manufacture.
• Acoustic absorbers have a wide range of applications. These include in particular aeronautics, where such elements are used to at least partially absorb the noise generated by aircraft engines and thus reduce its transmission to the external environment.
• turbofans are most common aviation engines.
• a turbofan engine comprises a fan and a gas generator incorporating at least a compressor, a combustion chamber, a turbine and a nozzle.
• the total noise produced by such a turbofan engine can therefore include jet, combustion, fan, compressor and turbine noise.
• the most dominant noise is usually that emitted by the blower, which can span a wide frequency band, as shown in Fig. 16, with tonal components corresponding to the passing frequencies of the fan blades.
• turbofan engines In order to increase the energy efficiency of turbofan engines, the general trend is to increase their bypass ratio, i.e. the proportion of the air flow impelled by the fan compared to that used to the combustion in the gas generator, and therefore the diameter of the fan. As a result, the fans of the latest generations of turbofan engines tend to rotate more slowly, and therefore emit noise at lower frequencies.
• bypass ratio i.e. the proportion of the air flow impelled by the fan compared to that used to the combustion in the gas generator, and therefore the diameter of the fan.
• acoustic absorbers such as honeycomb sandwich panels.
• each cell of the honeycomb can function as a Helmholtz resonator to reduce noise.
• the frequency range of acoustic attenuation of such absorbers is limited and, to be effective at low frequencies, they must be particularly bulky, which is all the more penalizing since the surface to be covered can be very large for turbojets with double flow and very high dilution rate.
• porous materials As an alternative to honeycomb sandwich panels, it has therefore been proposed to use porous materials, the individual pores of which act as Helmholtz resonators.
• most of the porous materials available have too low a mechanical strength, while the most resistant, such as for example the metallic material disclosed in US 7,963,364 B2, are excessively heavy.
• they provide significant attenuation only at resonant frequencies and do not absorb noise over a wide frequency range.
• Acoustic meta-materials with several layers superimposed in the direction of the thickness, produced by additive manufacturing, have been proposed in the French patent application publication FR 1 761 722, as well as by Guild, M. D., Rohde, C., Rothko, M. C., & Sieck, C. F. in “3D printed acoustic metamaterial Sound absorbers using functionally-graded sonie crystals”, Proceedings of Euronoise (2016).
• Acoustic meta-material can be understood as a periodically structured medium whose periodically repeated constituent units collectively affect the passage of acoustic waves.
• each superposed layer can present a lattice with a different periodicity, so as to widen its frequency range of attenuation frequencies.
• the present disclosure aims to propose, in a first aspect, an acoustic meta-material combining a high level of acoustic absorption with good mechanical resistance, including to abrasion.
• This acoustic meta-material may comprise a plurality of channels each having the same cross section with a hydraulic radius between 5 and 300 ⁇ m, these channels being arranged with a periodic spacing between adjacent channels between 2 and 600 ⁇ m.
• highly dense array of acoustic micro-channels capable of providing optimum acoustic absorption and/or impedance over a wide frequency band, with maximum absorptions at least at certain low frequencies such as those dominant in the emission spectrum of twin turbojet fans fluxes at high and very high dilution rates.
• the channels can have a substantially polygonal cross-section, for example triangular, square, rectangular or hexagonal.
• substantially polygonal is meant that the corners of the cross section may be rounded as a result of manufacturing constraints.
• the cross-section can however also be substantially round or oval.
• substantially round or oval is meant that the contour of the cross section may also have flats also because of manufacturing constraints.
• the acoustic metamaterial may comprise several pluralities of channels, each plurality of channels having a cross section and/or a periodic spacing of the channels that are different.
• these different pluralities of channels can be arranged in directly adjacent layers in a direction of the thickness of the metamaterial, such that the acoustic metamaterial comprises several layers stacked in the direction of the thickness, each layer comprising a plurality of channels having a different cross-section and/or periodic spacing of the channels. It is nevertheless also possible to vary the cross-section and/or the spacing of the channels in a plane perpendicular to the direction of the thickness of the meta-material.
• one or more of the channels may be inclined with respect to a direction of thickness of the meta-material, and in particular be helical. They can, alternatively or in addition, be bent in order also to increase their length.
• a second aspect of the present invention relates to a method of additive manufacturing of the acoustic meta-material of the first aspect.
• This additive manufacturing process may comprise several consecutive steps of depositing material to form, in each step, a stratum comprising a plurality of periodically repeated cells, separated by walls. Strata deposited in consecutive stages of material deposition can be stacked with their respective cells aligned so as to form the channels.
• the material used in the method according to this second aspect may comprise a thermoplastic polymer, and the deposition then be carried out by deposition of molten wire in order to allow the manufacture of sufficiently fine structures.
• the material used in this method could comprise a thermosetting resin, and the deposition of material then be carried out, analogously to the deposition of molten wire, by extrusion of this thermosetting resin.
• the material used in this process can also comprise, apart from the thermoplastic polymer or the thermosetting resin, solid particles in suspension, such as in particular fibers, and more particularly carbon fibers.
• solid particles such as, in particular, nanoparticles or microbeads, in particular made of silica, can also be envisaged. Thanks to these solid particles, the acoustic meta-material will be able to present a high mechanical and thermal resistance, as well as abradability properties.
• a third aspect of the present disclosure relates to another process for manufacturing an acoustic meta-material that also combines a high level of sound absorption with good mechanical resistance, including to abrasion.
• a mold can be produced by depositing a plurality of stacked strata which can each comprise a plurality of periodically repeated cells, separated by walls, the cells of the plurality of stacked strata can be aligned to form channels.
• the channels can be filled with a fluid material, which can then be solidified before removal from the mould.
• a meta-material comprising a highly dense periodic arrangement of columns which can also offer optimum acoustic absorption and/or impedance over a wide band of frequencies, with maximum absorptions at least at certain low frequencies such as those dominant in the emission spectrum of turbofan fans with high and very high bypass ratios.
• the hollow cells can in particular have a hydraulic radius between 5 and 300 ⁇ m, so as to obtain columns of corresponding width in the acoustic meta-material, while the walls can have a minimum width of between 2 ⁇ m and 600 ⁇ m to obtain thus a corresponding lateral gap between the columns. With these dimensions, it is possible to obtain sonic crystals with optimum acoustic absorption and impedance over wide frequency ranges including the dominant frequencies in the emission spectrum of high and very high bypass ratio turbofan jet engine fans. .
• the mold channels can have a length of between 1 and 150 mm, so as to obtain columns of corresponding height.
• the acoustic meta-material obtained by this process may have a thickness barely greater than this length, thus facilitating its integration, in particular in and around an aviation engine.
• the cells can be substantially polygonal, round or oval, so as to obtain columns of equivalent cross-section in the resulting acoustic meta-material. It is also possible to combine cells of different shapes in the same mould, or even in the same stratum of the mould.
• a shape and/or size of cells of different strata, among the stacked strata may be different, so as to vary the cross-section of the channels, and therefore of the columns, over their length, in order in particular to optimize the acoustic response of the acoustic metamaterial to several frequency bands.
• the mold can also comprise one or more lateral ducts between the channels, so as to form, when they are filled with the fluid material and the solidification of the latter, spacers and other lateral reinforcements between the columns of the acoustic meta-material.
• the latter may be made of a water-soluble material comprising, for example, a polyvinyl alcohol (PVA), a copolymer of butanediol and vinyl alcohol (BVOH), or a polylactic acid (PLA).
• PVA polyvinyl alcohol
• BVOH butanediol and vinyl alcohol
• PLA polylactic acid
• the additive manufacturing of the mold can be carried out by deposition of a wire of extruded material, and in particular by a method of depositing molten wire.
• the material used to manufacture the mold can therefore comprise a thermoplastic polymer, but a thermosetting resin can also be envisaged.
• the fluid material used in the step of filling the mold can comprise a resin, such as for example an epoxy resin, and the step of solidifying the material of the mold then comprises a polymerization of the resin.
• This polymerization can be activated and/or accelerated thermally, although other means of activation, for example by ultraviolet light, are also possible.
• a molten thermoplastic polymer as a fluid material in the filling step.
• the fluid material may comprise solid particles in suspension, such as in particular silica microbeads or nanoparticles, or fibers, and in particular carbon fibers.
• a fourth aspect of this disclosure pertains to the acoustic metamaterial fabricated by the fabrication method of the third aspect and having a plurality of columns extending from a common base.
• a fifth aspect of this disclosure relates to a turbomachine, in particular a gas turbine engine such as a turbofan engine, comprising the acoustic meta-material of the first aspect or of the fourth aspect, as an acoustic absorber.
• the acoustic meta-material could be integrated into a wall delimiting a fan air stream and/or into a gas generator casing.
• - Figure 2 is a cutaway view in thickness of a first acoustic meta-material suitable for use as an acoustic absorber in the turbofan engine of Figure 1
• - Figures 3A to 3G are cross-sectional views, along plan III-III, of different possible alternative shapes of the channels of the meta-material of figure 2
• FIG. 4 is a graph illustrating the acoustic absorption coefficient as a function of frequency, for several acoustic meta-materials with channels having different shapes and widths,
• FIG. 5 is a sectional view in thickness of an alternative embodiment of the acoustic meta-material, with channels of different widths on different layers of the acoustic meta-material,
• FIG. 6 is a graph illustrating the acoustic absorption coefficient as a function of frequency, for several examples of multilayer acoustic meta-material,
• FIGS. 7A, 7B and 7C are sectional views in thickness of several other alternative embodiments of the acoustic meta-material
• FIG. 8 illustrates a device for implementing an additive manufacturing process
• FIGS. 9A and 9B illustrate two alternative material deposition paths for the manufacture of a stratum
• FIG. 10 is a perspective view of a second acoustic meta-material suitable for use as an acoustic absorber in the turbofan engine of FIG. 1, FIGS.
• FIG. 10 is a graph illustrating the acoustic absorption coefficient as a function of frequency, for several acoustic meta-materials with channels having different shapes and widths
• figure 13 is a view in cross-section of an alternative embodiment of the second acoustic meta-material, with columns of different widths on different layers of the acoustic meta-material
• the Figure 14 is a sectional view in thickness of another alternative embodiment of the second acoustic meta-material, with spacers laterally connecting the columns of the acoustic meta-material
• Figure 15 illustrates a step of filling the mold of the second meta -acoustic material
• FIG. 16 is a graph illustrating the intensity of the noise emitted by a turbofan engine as a function of frequency.
• FIG. 1 schematically illustrates a turbomachine 1, more specifically a turbofan engine.
• this turbofan engine may include a fan 2, a low pressure compressor 3, a high pressure compressor 4, a combustion chamber 5, a high pressure turbine 6, a low pressure turbine 7 and a nozzle 8.
• the assembly can be surrounded by a nacelle 9.
• the compressors 3.4, the chamber of combustion 5 and the turbines 6, 7 together form the gas generator 10, which may itself be surrounded by a shroud 11 terminating in the nozzle 8.
• an air stream 12 of the fan 2 may be defined between the fairing 11 of the gas generator 10 and an internal wall 13 of the nacelle 9.
• the high pressure turbine 6 can be connected to the high pressure compressor 4 by a first rotary shaft 14 for driving the latter, while the low pressure turbine 7 can be connected to the fan 2 and to the low pressure compressor 3 by a second rotary shaft 15 coaxial with the first rotary shaft 14, in an analogous manner.
• a reduction gear 16 can be mechanically interposed between the second rotary shaft 15 and the fan 2, in order to reduce the speed of rotation of the fan 2 and prevent the blade tips fan 2 reach excessive speeds.
• noise absorbers 17 can be integrated into the internal wall 13 of the nacelle 9, in particular upstream and downstream of the blades of the fan 2. As illustrated, it is also possible to integrate noise absorbers 17 in the fairing 11 of the gas generator 10, or even in the casing of the latter.
• the sound absorbers 17 are formed by honeycomb sandwich panels.
• these panels can represent a significant penalty in terms of mass and size.
• Figures 2 to 3G illustrate several embodiments of a noise absorber 17 formed by an acoustic meta-material 100 that can effectively replace the honeycomb sandwich panel noise absorbers, with less weight and bulk, and even be arranged directly opposite the blades of the fan 2 as an abradable material 18.
• this acoustic meta-material 100 can comprise a plurality of channels 101, of high density and arranged periodically and extending from an exposed surface 102 of the meta-material 100 to its base 103.
• the channels 101 can be separated from each other by walls 104.
• each channel 101 may have a substantially square outline.
• substantially polygonal shapes such as for example substantially rectangular, diamond-shaped, triangular or hexagonal shapes are also possible, as illustrated respectively in FIGS. 3B, 3C, 3D and 3E.
• Non-polygonal shapes such as for example substantially round or oval shapes, can also be envisaged, as illustrated respectively in FIGS. 3F and 3G.
• each channel 101 can have a hydraulic radius r h of, for example, between 5 ⁇ m and 300 ⁇ m, which, for channels 101 with a square or round section, corresponds to a width W between 10 ⁇ m and 600 ⁇ m, although a shape factor may be applied to account for the edge effects of channels of differently shaped cross sections. Spacing periodic t between adjacent channels 101 can be for example between 2 ⁇ m and 600 ⁇ m.
• FIG. 4 illustrates the absorption coefficient a [ ALPHA] as a function of the acoustic frequency f for examples of acoustic meta-materials 100 with different values of width W and periodic spacing t of the channels 101.
• the curves 401, 402, 403 and 404 correspond to meta- acoustic materials 100 with substantially square channels 101 with widths W and periodic spacings t of, respectively, 133 and 2 ⁇ m, 175 and 50 ⁇ m, 215 and 100 ⁇ m, and 265 and 155 ⁇ m.
• the maximum absorption coefficient is close to one, and corresponds to substantially the same frequency f between 2000 and 3000 Hz for the different values of W and t, the frequency band of absorption widens. with a decrease in W and t.
• the meta-material 100 In order to widen the sound absorption range of the meta-material 100, it is possible to combine pluralities of channels 101 with different periodic spacings and/or cross-sections of different shapes and sizes in the same meta-material 100. Thus, it is possible to envisage that the meta-material 100 comprises several superimposed layers in a direction of the thickness, the channels 101 having a different cross-section and/or a different spacing per layer. It is even possible to include therein layers with different functionalities than sound absorption, and therefore not comprising regularly spaced channels or having the claimed dimensions.
• the channels of the different layers can be aligned and the mesh pitch, that is to say the sum of the width W and the spacing t, corresponding to each layer be an integer multiple of the minimum mesh pitch among the different layers.
• the mesh pitch of each layer can be 2 n times the minimum mesh pitch among the different layers, where n is an integer.
• FIG. 5 illustrates a first example of acoustic meta-material 100 with five layers 100i, 100 2 , IOO3, 100 4 and 100 5 superimposed, having respective thicknesses hi, h 2 , h 3 , h 4 and h 5 of 6 mm each and channels 101 of square section, and where the width W 4 of the channels of the first layer 100i is 496 ⁇ m, the width W 2 of the channels of the second layer 100 2 is 148 ⁇ m, the width W 3 of the channels of the third level 100 3 is 496 pm, the width W 4 of the channels of the fourth level 100 4 is 1192 pm, and the width W 5 of the channels of the fifth level 100 5 is 496 pm, with a constant spacing t between channels 101 of 200 ⁇ m in each of the layers, so as to obtain an absorption coefficient a close to 1 over a wide range of frequencies f ranging from 2500 to 6500 Hz, as illustrated by curve 601 of figure 6.
• the acoustic meta-material may comprise only two superposed layers with respective thicknesses of 1 and 29 mm, and where the width of the channels of the first layer is 100 ⁇ m and that of the channels of the second layer is 9 mm, with a constant spacing t of 200 ⁇ m between channels 101 in each of the layers, so as to obtain a high absorption coefficient a over a frequency range f ranging from 1000 to 3000 Hz, as illustrated by the curve 602 of FIG. 6.
• the acoustic meta-material can comprise thirty superimposed layers, each with a thickness of 1 millimeter and a constant spacing t between channels of 200 ⁇ m, and a width of the channels of 4 .11 mm for layers 1, 6, 12, 15 to 17, 20, and 22 to 24; 8.42 mm for layers 2, 8, 11, 18, 27 and 29; 69.4 ⁇ m for layers #3, 19, 21, 25 and 26; 1.95 mm for layers 4, 5, 7, 13, 14 and 30; and 338.8 ⁇ m for layers #9, 10 and 28; so as to obtain a high absorption coefficient a over a wider range of frequencies f ranging from 1000 to 4500 Hz, as illustrated by curve 603 of FIG. 6.
• the base 103 and the walls 104 of the acoustic meta-material 100 can be made of thermoplastic polymer, for example polyetherimide (PEI) or polyetheretherketone (PEEK), or of thermosetting resin, for example an epoxy resin such as that forming the abradable material sold by 3M® under the name Scotch-Weld® EC-3524 B/A.
• thermoplastic polymer for example polyetherimide (PEI) or polyetheretherketone (PEEK)
• thermosetting resin for example an epoxy resin such as that forming the abradable material sold by 3M® under the name Scotch-Weld® EC-3524 B/A.
• thermosetting resin for example an epoxy resin such as that forming the abradable material sold by 3M® under the name Scotch-Weld® EC-3524 B/A.
• solid particles embedded in the mass, for example fibers, and in particular carbon fibers, microspheres, for example glass microbeads, or nanoparticles such as silica
• the acoustic properties (eg impedance and absorption) of the acoustic metamaterial 100 can be simulated with the transfer matrix method or “TMM” (acronym for “Transfer Matrix Method”).
• TMM transfer matrix method
• the equivalent fluid wavenumber and the equivalent characteristic impedance can be calculated using the Johnson-Champoux-Allard-Lafarge (JCAL) semi-phenomenological model describing the visco-inertial dissipative effects within of a porous medium, from six parameters: porosity, tortuosity, viscous and thermal length and viscous and thermal permeability, which can be simulated with the multi-scale asymptotic method or "MAM" (acronym for Multi-scale Asymptotic Method).
• JCAL Johnson-Champoux-Allard-Lafarge
• the equivalent fluid wavenumber, and the equivalent characteristic impedance can be calculated separately for each layer.
• the shape, dimensions and arrangement of the channels 101 of the acoustic meta-material 100 can be defined according to the frequency ranges for which an impedance and/or absorption is desired.
• optimal acoustics by applying an optimization algorithm, such as for example the Nelder-Mead iterative optimization method. At each iteration of the optimization algorithm, these dimensional parameters of the acoustic meta-material 100 can be adjusted to meet other constraints, such as for example that of avoiding the obstruction of the channels 101 of each layer by the layers adjacent.
• the acoustic meta-material 100 can be produced by an additive manufacturing process based on the extrusion of material, such as for example the molten wire deposition process used for thermoplastic materials. These processes, which are particularly suitable for manufacturing complex shapes with thin walls, include several consecutive material deposition steps. In each of these steps, an extruder head 200 can move along a path 201 in an X-Y transverse plane by depositing the material 202, which then solidifies so as to form a stratum 203. By moving this X-Y transverse plane along an orthogonal direction Z after the deposition of each stratum 203, it is possible to stack these strata 203 to form the acoustic meta-material 100, as illustrated in FIG. 8.
• an extruder head 200 can move along a path 201 in an X-Y transverse plane by depositing the material 202, which then solidifies so as to form a stratum 203.
• each stratum 203 can comprise a plurality of cells 204 periodically repeated, separated by the walls 104 formed by the deposition of the material 202, and the strata 203 deposited in the consecutive stages of deposition of material can be stacked with their respective cells 204 aligned. In order to avoid at least partially the interlacing of the material
• the plot 201 can be in zig ⁇ zag, as illustrated in Figure 9A.
• a gap O can be maintained between the angles 205 of the trace 201 at these intersections.
• an acoustic meta-material 100' may comprise a plurality of columns 10 arranged periodically and extending from a common base 103' to an exposed face 102' of the meta-material. material 100'.
• the columns 10 can be separated from each other by interstices 104'.
• Each column 10 can have a total height H of, for example, between 1 and 150 mm.
• each column 10 may have a substantially square outline.
• substantially polygonal shapes such as for example substantially rectangular, diamond-shaped, triangular or hexagonal shapes are also possible, as illustrated respectively in FIGS. 11B, 11C, 11D and 11E.
• Non-polygonal shapes such as for example substantially round or oval shapes, are also possible, as illustrated respectively in FIGS. 11F and 11G.
• the cross section of each column 10 can have a hydraulic radius r h of, for example, between 5 ⁇ m and 300 ⁇ m, which, for columns 10 with a square or round section, corresponds to a width W between 10 pm and 600 pm, although a form factor may be applied to take into account the effects edge of columns of cross sections of different shape.
• the columns 10 can have a periodic spacing s between adjacent columns 10 of for example between 2 ⁇ m and 600 ⁇ m.
• the dimensions in these intervals allow a particularly high absorption coefficient a [ALPHA] for frequencies f between 200 and 10000 Hz, frequencies typically dominant in the noise of a turbofan engine at high or very high dilution rate.
• the curve 1201 illustrates the absorption coefficient a [ALPHA] as a function of frequency for a meta-material 100' comprising columns 10 of 30 mm in height, with a square cross-section having a width W of 130 ⁇ m, and a periodic spacing s of 100 ⁇ m
• curve 1202 illustrates that for a meta-material 100' comprising columns 10 of square cross-section and the same height, but a width W of 1.15 mm and a spacing periodic s of 200 pm.
• columns 10 with cross-sections of different shapes and sizes in the same meta-material 100', or even to have different shapes and sizes (for example different maximum widths) at different heights from of the base in order to adapt the acoustic meta-material 100' to the attenuation of several different acoustic frequencies, as illustrated in FIG. 13. It is even possible to include therein layers with different functionalities than acoustic absorption, and therefore not comprising regularly spaced columns or having the aforementioned dimensions. Furthermore, in order to laterally reinforce the columns 10, adjacent columns 10 can be locally connected by spacers 105' formed integrally to the columns, as illustrated in FIG. 14.
• the base 103' and the columns 10 of the acoustic meta-material 100' can be made of polymer, for example polyepoxide.
• the acoustic meta-material 100' can be produced by molding.
• a mold 210 can be produced by an additive manufacturing process based on the extrusion of material, such as for example the molten wire deposition process used for thermoplastic materials.
• an extruder head 200 can move along a path 201 in an X-Y transverse plane depositing the material 202, which then solidifies so as to form a stratum 203.
• This transverse plane X-Y along an orthogonal direction Z after the deposition of each stratum 203, it is possible to stack these strata 203 to form the mold 210, as illustrated in FIG. 8.
• Each stratum 203 can comprise a plurality of cells 204 periodically repeated , separated by walls 205 formed by the deposition of material 202, and the strata 203 deposited in the consecutive stages of deposition of material can be stacked with their respective cells 204 aligned, so as to form channels 206 with different sizes, shapes and spacings corresponding to those of the columns 10 .
• the maximum width of the channels 206 can be substantially equal to the maximum width W of the columns 10
• the minimum thickness of the walls 205 can be substantially equal to the minimum spacing t' between the columns 10
• the length of the channels 206 can be substantially equal to the height H' of the columns 10 .
• each channel 206' in the X-Y transverse plane can vary as a function of height in the orthogonal direction.
• the mold 210 can also include side conduits between these channels 206 in order to form the spacers 105'.
• the channels 206' of the different layers can be aligned and the mesh pitch, i.e. the sum of the width W and the spacing s, corresponding to each layer be an integer multiple of the minimum mesh pitch among the different layers.
• the mesh pitch of each layer can be 2 n times the minimum mesh pitch among the different layers, where n is an integer.
• the line 201 can be in zigzag, as illustrated in the figure. 9A.
• a fluid material 220 can be introduced into the mold 210, so as to fill the channels 206 and other cavities of the mold 210, as illustrated in FIG. 15.
• This fluid material 220 may be a thermosetting resin, in particular an epoxy resin mixed with a crosslinking agent, such as that forming the abradable material sold by 3M® under the name Scotch-Weld® EC-3524 B/A.
• a thermoplastic polymer such as a polyetherimide (PEI) or polyetheretherketone (PEEK), in fusion.
• the fluid material 220 can also comprise solid particles in suspension, for example beads or nanoparticles in silica or fibers, for example in carbon, which will remain embedded in the mass after solidification of the fluid material 220.
• the filling of the cavities of the mold 210 with the fluid material 220 can be carried out by simple gravity, or at least be assisted by a pressure gradient. Once the fluid material 220 fills the cavities of the mold 210, it can harden inside these cavities. This solidification can be thermally induced, or at least accelerated, in a curing step, in particular when the fluid material 220 is a thermosetting resin.
• the mold 210 can be removed so as to release the acoustic meta-material 100' therefrom.
• the material of the mold 210 can be a water-soluble material and in particular a water-soluble thermoplastic polymer, such as, for example, a polyvinyl alcohol (PVA), a copolymer of butanediol and vinyl alcohol (BVOH), or a polylactic acid (PLA ), and the removal of the mold 210 can be carried out by leaching this water-soluble material, for example in an ultrasonic bath, optionally heated to a temperature of, for example, 60 to 80° C., for 3 to 5 hours.
• the acoustic meta-material 100' is thus released from its mold 210, it can be dried, for example in an oven at 70° C. for one hour.

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