Bonded double wall seal assembly

A thrust reverser assembly for an aircraft engine nacelle, comprising:

• a cowl mounted to the nacelle;
• and
• a fire seal assembly coupled with the cowl, the fire seal assembly comprising:
• a first wall extending from a compression side of the fire seal assembly to a fastened side of the fire seal assembly;
• a second wall interior of the first wall and extending from the compression side to the fastened side of the seal assembly, the second wall having an upper portion adjacent to the compression side of the seal assembly and a semi-permeable portion extending from the upper portion to the fastened side of the seal assembly, wherein the first wall is bonded to the second wall at a low stress point adjacent to the fastened side of the seal assembly;
• and
• a stiffening member embedded within the upper portion of the second wall adjacent to the compression side of the fire seal assembly;
• wherein when the fire seal assembly is pressurized, the first wall forms a first C-shape and the second wall forms a second C-shape interior of the first C-shaped first wall such that the seal assembly has a nested double C-shaped cross-section with respect to a longitudinal axis of the seal assembly and such that the first wall and the second wall define an insulated pocket.

A method for manufacturing a seal assembly, the seal assembly comprising:

• a first wall extending from a compression side of the seal assembly to a fastened side of the seal assembly;
• a second wall interior of the first wall and extending from the compression side of the seal assembly to the fastened side of the seal assembly, the second wall having an upper portion adjacent to the compression side of the seal assembly and a semi-permeable portion extending from the upper portion to the fastened side of the seal assembly, wherein the first wall is bonded to the second wall at a low stress point adjacent to the fastened side of the seal assembly;
• and
• a stiffening member embedded within the upper portion of the second wall adjacent to the compression side of the seal assembly;
• wherein when the seal assembly is pressurized, the first wall forms a first C-shape and the second wall forms a second C-shape interior of the first C-shaped first wall such that the seal assembly has a nested double C-shaped cross-section with respect to a longitudinal axis of the seal assembly and such that the first wall and the second wall define an insulated pocket,
• the method comprising:
• forming the second wall from a first elastomeric material and forming a plurality of perforations in the second wall, the second wall having a first inner wall end and a second inner wall end opposite the first inner wall end, the second wall having the upper portion adjacent to the first inner wall end and the semi-permeable portion extending from the upper portion to the second inner wall end;
• embedding the stiffening member within the upper portion of the second wall adjacent to the first inner wall end of the second wall;
• forming the first wall from a second elastomeric material, the first wall having a first outer wall end and a second outer wall end opposite the first outer wall end;
• coupling the second wall to the first wall at a first low stress point adjacent to the first inner and outer wall ends and at a second low stress point adjacent to the second inner and outer wall ends, such that the second wall is interior of the first wall;
• and
• pressurizing the seal assembly such that the first wall forms the first C-shape and the second wall forms the second C-shape interior of the first C-shaped outer wall such that the seal assembly has the nested double C-shaped cross-section with respect to the longitudinal axis of the seal assembly and such that the insulated pocket is defined between the second wall and the first wall.

A seal assembly, comprising:

• a first wall extending from a compression side of the seal assembly to a fastened side of the seal assembly;
• a second wall interior of the first wall and extending from the compression side of the seal assembly to the fastened side of the seal assembly, the second wall having an upper portion adjacent to the compression side of the seal assembly and a semi-permeable portion extending from the upper portion to the fastened side of the seal assembly, wherein the first wall and the second wall of the seal assembly are formed as a unitary piece;
• and
• a stiffening member embedded within the upper portion of the second wall adjacent to the compression side of the seal assembly;
• wherein when the seal assembly is pressurized, the first wall forms a first C-shape and the second wall forms a second C-shape interior of the first C-shaped first wall such that the seal assembly has a nested double C-shaped cross-section with respect to a longitudinal axis of the seal assembly and such that the first wall and the second wall define an insulated pocket.