Cascade segment for thrust reverser with repeating modular units, and method of manufacturing same

A cascade segment for a thrust reverser, the cascade segment comprising:

• a plurality of individual vane elements, with each individual vane element of the plurality of individual vane elements including—
• a vane having a first vane end and a second vane end,
• a first flange extending angularly from the first vane end to a first flange end, and
• a second flange extending angularly from the second vane end to a second flange end in approximately the same direction as the first flange, such that the individual vane element is generally U-shaped,
• wherein each of the first and the second flanges diverge from being perpendicular to the vane by an amount equal to a thickness of the respective first or the respective second flange over a desired vane spacing distance, such that when one of the individual vane elements is inserted into another of the individual vane elements the desired vane spacing distance is established between their respective vanes;
• a plurality of first modular units, with each first modular unit including a first column of the individual vane elements oriented in a first direction, with each of the vanes having a concave cross-section;
• a plurality of second modular units, with each second modular unit including a second column of the individual vane elements oriented in a second direction which is opposite the first direction, with each of the vanes having a convex cross-section;
• wherein the first modular units are positioned alternatingly with and adjacent to the second modular units in the cascade segment;
• and
• a frame extending at least partly around and securing the pluralities of the first and the second modular units together.

A method of manufacturing a cascade segment, the method comprising:

• forming a plurality of individual vane elements, with each individual vane element of the plurality of individual vane elements including—
• a vane having a first vane end and a second vane end,
• a first flange extending angularly from the first vane end to a first flange end, and
• a second flange extending angularly from the second vane end to a second flange end in approximately the same direction as the first flange, such that the individual vane element is generally U-shaped,
• wherein each of the first and the second flanges diverge from being perpendicular to the vane by an amount equal to a thickness of the respective first or the respective second flange over a desired vane spacing distance, such that when one of the individual vane elements is inserted into another of the individual vane elements the desired vane spacing distance is established between their respective vanes;
• assembling the plurality of individual vane elements to form—
• a first modular unit including a first column of the individual vane elements oriented in a first direction, and
• a second modular unit including a second column of the individual vane elements oriented in a second direction which is opposite the first direction;
• and
• positioning the first modular unit adjacent to the second modular unit in the cascade segment.