Method of making a cascade basket for a thrust reverser
AssigneeThe Boeing Company
InventorMichael L. Vermilye
Life of this patent
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Abstract
A thrust reverser cascade basket and method including an elongated metal frame having elongated metal strongbacks and metal transverse end portions joining opposite ends of respected strongbacks. Reinforced hard plastic is pressure injection molded on the strongbacks, and transverse vanes formed of the plastic extend between the strongbacks and are integral therewith. The strongbacks have openings having the plastic molded therein, the openings being between the vanes, and substantially all plastic knit lines are formed along strongback surfaces, spaced adjacent mid-span locations between the vanes. The vanes are free of the knit lines.
Claims12
A method of making a hybrid thrust reverser cascade basket, comprising:
- positioning a skeletal metal elongated frame in a mold;
- said frame having transversely spaced, elongated metal strongbacks, the frame having metal transverse opposite ends joining opposite ends of respective strongbacks;
- pressure injecting reinforced thermosetting plastic into the mold directly over the frame to adhere to the strongbacks and to form transversely extending plastic vanes in the mold so as to be joined to the strongbacks, the vanes being spaced in the elongated direction and extending between the strongbacks and integral therewith to form a complete hybrid structure capable of supporting both thrust reverser flow and fatigue loading;
- the strongbacks having openings between the vanes and spaced in the elongated direction, the plastic being injected through and into the openings for strengthening engagement;
- and
- forming substantially all plastic knit lines along strongback surfaces, and spacing the knit lines adjacent mid-span locations between the vanes.
Dependencies are inferred from the claim text.