Dual function cascade integrated variable area fan nozzle and thrust reverser

1. A gas turbine engine comprising:

an outer housing that extends circumferentially about a fan to establish a bypass passage extending between the outer housing and an inner housing;

a low pressure compressor and a high pressure compressor, wherein the inner housing surrounds the low pressure compressor;

a gear train defining a gear reduction ratio;

a combustion section in communication with the low pressure compressor and the high pressure compressor;

a high pressure turbine coupled for rotation with a first spool to rotationally drive the high pressure compressor;

a low pressure turbine coupled for rotation with a second spool to rotationally drive the gear train, and the fan driven through the gear train;

at least one integrated mechanism coupled to the outer housing, the at least one integrated mechanism including a variable area nozzle and a thrust reverser, the thrust reverser and the variable area nozzle having a common part;

wherein the thrust reverser includes a cascade section having a first set of apertures angled in a first direction and a second set of apertures angled in a second, different direction;

at least one actuator coupled to the at least one integrated mechanism;

a controller that communicates with the at least one actuator to selectively move the common part between a plurality of axial positions in operation with respect to a centerline axis of the gas turbine engine, wherein the plurality of axial positions include a stowed position, an intermediate position and a deployed position;

wherein the common part covers the cascade section in the stowed position, the common part is spaced apart from the outer housing in the intermediate position to provide an auxiliary passage and expose the first set of apertures, and the common part exposes the second set of apertures in the deployed position;

wherein the common part includes a hollow sleeve that extends about the cascade section in the stowed and intermediate positions, and the thrust reverser includes a blocker door pivotably connected to the common part; and

a link including a first portion slideably connected to the blocker door and a second portion connected to the inner housing, and wherein the blocker door includes a slot that receives and retains the first portion of the link.

2. The gas turbine engine of claim 1 , wherein the gear train is an epicycle gear train.

3. The gas turbine engine of claim 1 , wherein the first direction is a forward direction, and the second direction is an aft direction relative to the centerline axis.

4. The gas turbine engine of claim 3 , wherein the common part does not expose the second set of apertures in the intermediate position.

5. The gas turbine engine of claim 4 , wherein the first set of apertures and the second set of apertures are arranged in circumferential rows about the cascade section such that there are a larger number of circumferential rows in the second set of apertures than in the first set of apertures.

6. The gas turbine engine of claim 5 , wherein the gear train is an epicycle gear train.

7. The gas turbine engine of claim 6 , further comprising a bypass ratio of greater than 10, wherein the gear reduction ratio is greater than 2.5, and the low pressure turbine rotationally drives the low pressure compressor.

8. The gas turbine engine of claim 7 , wherein the cascade section includes airfoil shaped vanes between the apertures.

9. A method of controlling a gas turbine engine comprising:

providing an outer housing that extends circumferentially about a fan to establish a bypass passage between the outer housing and an inner housing;

providing at least one integrated mechanism coupled to the outer housing, the at least one integrated mechanism including a variable area nozzle and a thrust reverser, the thrust reverser and the variable area nozzle having a common part, and the thrust reverser including a cascade section having a first set of apertures angled in an aft direction and a second set of apertures angled in a forward direction with respect to a centerline axis of the gas turbine engine;

rotationally driving a low pressure compressor coupled to a low pressure turbine;

rotationally driving the fan through a gear train coupled to the low pressure turbine; and

moving the common part between a stowed position and an intermediate position to direct discharge bypass flow in the aft direction and enhancing operation of the fan;

moving the common part between the intermediate position and a deployed position exposing the second set of apertures, and directing discharge bypass flow in the forward direction, generating a reverse thrust force, wherein the common part is spaced apart from the outer housing to provide an auxiliary passage and expose the first set of apertures in the intermediate position, but does not expose the second set of apertures in the stowed or intermediate positions; and

pivoting a blocker door into the bypass passage in the deployed position, but not in the stowed or intermediate positions, to deflect discharge flow from the bypass passage radially outwards through the auxiliary passage with respect to the centerline axis, wherein a link includes a first portion slideably connected to the blocker door and a second portion non-slideably connected to the inner housing.

10. The method of claim 9 , wherein the common part includes a hollow sleeve that extends about the cascade section in the stowed and intermediate positions, the gear train defines a gear reduction ratio greater than 2.5, and further comprising a bypass ratio greater than 10.

11. The method of claim 10 , wherein the hollow sleeve is moveable between a plurality of axial positions with respect to the centerline axis, and wherein the plurality of axial positions comprise the stowed position, the intermediate position, and the deployed position.

12. The method of claim 11 , wherein at least one actuator is coupled to the at least one integrated mechanism, and the steps of moving the common part include moving the at least one actuator to move the hollow sleeve with respect to the centerline axis.

13. The method of claim 12 , wherein the at least one integrated mechanism includes at least two integrated mechanisms.

14. The method of claim 13 , wherein each of the two integrated mechanisms is coupled to a respective semi-circular portion of the outer housing.

15. The method of claim 9 , wherein the common part seals against the outer housing in the stowed position and covers the cascade section such that the bypass flow exits axially through a rear exhaust of the bypass passage established by the variable area fan nozzle.

16. The method of claim 15 , wherein:

the outer housing extends circumferentially about the fan to establish a bypass ratio greater than 10;

the gear train is an epicycle gear train defining a gear reduction ratio greater than 2.5; and

the common part includes a hollow sleeve that extends about the cascade section in the stowed and intermediate positions.

17. The method of claim 16 , wherein:

the hollow sleeve is moveable between a plurality of axial positions with respect to the centerline axis; and

the plurality of axial positions comprise the stowed position, the intermediate position, and the deployed position.

18. The method of claim 17 , wherein the first set of apertures and the second set of apertures are arranged in circumferential rows about the cascade section such that there are a larger number of circumferential rows in the second set of apertures than in the first set of apertures, and such that reverse thrust force due to directing discharge flow through the second set of apertures overcomes any thrust force due to directing discharge flow from the first set of apertures.

19. The method of claim 18 , wherein at least one actuator is coupled to the at least one integrated mechanism, and the steps of moving the common part include moving the at least one actuator to move the hollow sleeve with respect to the centerline axis.

20. The method of claim 19 , wherein the cascade section includes airfoil shaped vanes between the apertures.

21. The method of claim 20 , wherein the blocker door is pivotably connected to the common part.

22. The method of claim 21 , wherein the first set of apertures are arranged in two circumferential rows.

23. The method of claim 22 , wherein the blocker door includes a slot that receives and retains the first portion of the link.

24. The method of claim 23 , wherein the slot has a t-shaped cross section, and the first portion of the link includes laterally extending slide members that slide along the slot to cause the blocker door to pivot into the bypass passage in response to the moving the common part between the intermediate position and the deployed position, but not in response to the moving the common part between the stowed position and the intermediate position.