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;
• 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 fire seal assembly, comprising:

• forming an inner wall from a first elastomeric material and forming a plurality of perforations in the inner wall, the inner wall having a first inner wall end and a second inner wall end opposite the first inner wall end, the inner wall having an upper portion adjacent to the first inner wall end and a semi-permeable portion extending from the upper portion to the second inner wall end;
• embedding a stiffening member within the upper portion of the inner wall adjacent to the first inner wall end of the inner wall;
• forming an outer wall from a second elastomeric material, the outer wall having a first outer wall end and a second outer wall end opposite the first outer wall end;
• coupling the inner wall to the outer 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 inner wall is interior of the outer wall;
• and
• pressurizing the fire seal assembly such that the outer wall forms a first C-shape and the inner wall forms a second C-shape interior of the first C-shaped outer wall such that the fire seal assembly has a nested double C-shaped cross-section with respect to a longitudinal axis of the fire seal assembly and such that an insulated pocket is defined between the inner wall and the outer wall.