EP0747547B1 - Method of fabrication of a plate or the like with structural and acoustic features and plate obtained this way - Google Patents

Method of fabrication of a plate or the like with structural and acoustic features and plate obtained this way Download PDF

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Publication number
EP0747547B1
EP0747547B1 EP96450012A EP96450012A EP0747547B1 EP 0747547 B1 EP0747547 B1 EP 0747547B1 EP 96450012 A EP96450012 A EP 96450012A EP 96450012 A EP96450012 A EP 96450012A EP 0747547 B1 EP0747547 B1 EP 0747547B1
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EP
European Patent Office
Prior art keywords
skins
skin
glue
panel
order
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Expired - Lifetime
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EP96450012A
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German (de)
French (fr)
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EP0747547A1 (en
Inventor
Alain Fournier
Bruno Pelouze
Pierre Tiefenbach
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Aerospatiale Matra
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Airbus Group SAS
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/86—Sound-absorbing elements slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E04B2001/748—Honeycomb materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24149—Honeycomb-like
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y10T428/24331—Composite web or sheet including nonapertured component

Description

La présente invention a trait à un procédé de fabrication d'un panneau ou analogue à propriétés structurale et acoustique et plus précisément d'une structure du type sandwich formée d'une âme alvéolaire revêtue sur ses deux faces, présentant des capacités à la fois de résistance à des charges importantes et d'atténuation acoustique. Un procédé de ce genre est décrit dans le document US-A-5 037 498.The present invention relates to a method of manufacturing a panel or analogous to structural and acoustic properties and more precisely to a sandwich type structure formed by a honeycomb core coated on both faces, having both resistance to loads capacities important and acoustic attenuation. A process of this kind is described in document US-A-5,037,498.

Bien que décrite ci-après dans son application à la réalisation notamment de cloisons de fuselage d'aéronefs, l'invention est évidemment susceptible d'applications dans tout autre domaine où s'avère nécessaire ou souhaitable d'utiliser une structure du type panneau sandwich alliant légèreté, grande résistance mécanique et propriétés acoustiques.Although described below in its application to the realization in particular of aircraft fuselage bulkheads, the invention is obviously susceptible applications in any other area where is necessary or desirable to use a sandwich panel structure combining lightness, great mechanical resistance and acoustic properties.

On sait que les aéronefs du type turbopropulseur posent des problèmes d'isolation acoustique de l'habitacle intérieur vis à vis notamment des bruits et vibrations engendrées par les moteurs, les hélices, des bruits aérodynamiques, etc...We know that turboprop aircraft pose problems sound insulation of the interior passenger compartment, in particular against noise and vibrations generated by engines, propellers, aerodynamic noise, etc ...

Jusqu'à présent on n'a pas encore résolu de manière satisfaisante l'isolation phonique en particulier de la cabine passager vis à vis de la partie cargo et l'invention vise précisément à proposer un nouveau type de panneau apte à la réalisation de cloisons de cabine passager.So far we have not yet resolved satisfactorily soundproofing in particular of the passenger cabin with respect to the part cargo and the invention aims precisely to propose a new type of panel suitable for the production of passenger cabin partitions.

De telles cloisons doivent nécessairement être des éléments structuraux, c'est-à-dire aptes à supporter des charges ou efforts, en particulier normalement au plan des cloisons, pouvant être très importants. Elles doivent en effet contenir, côté soute, les bagages en cas de crash de l'aéronef, ou résister en cas de dépressurisation brutale de la cabine ou de la soute.Such partitions must necessarily be structural elements, that is to say capable of supporting loads or efforts, in particular normally in terms of partitions, which can be very large. They must indeed contain, on the hold side, baggage in the event of an aircraft crash, or resist abrupt depressurization of the cabin or hold.

De plus, ces cloisons doivent présenter, côté cabine, un aspect esthétique, c'est-à-dire être décorées en accord avec le reste de la cabine.In addition, these partitions must have an aspect, cabin side aesthetic, that is to say being decorated in accordance with the rest of the cabin.

Il n'existe pas actuellement de panneaux satisfaisant d'une part aux contraintes habituelles de légèreté et de résistance au feu, mais également aux différents impératifs ci-dessus.There are currently no signs satisfying on the one hand the usual constraints of lightness and fire resistance, but also different imperatives above.

Les panneaux structuraux destinés à réduire par exemple les effets d'un crash n'ont pas de propriétés de traitement du bruit.Structural panels intended to reduce for example the effects of a crash have no noise processing properties.

Par ailleurs, on connaít des panneaux du type sandwich formé d'une âme en particulier en nid d'abeilles, flanquée, d'un côté, d'une feuille métallique perforée et, de l'autre côté, d'une feuille métallique non perforée, utilisés pour leurs propriétés d'atténuation du bruit, par exemple comme revêtements en certains emplacements de la nacelle de turbomoteurs afin d'absorber au moins partiellement l'énergie sonore des flux de gaz à grande vitesse.Furthermore, there are known sandwich type panels formed of a core in particular honeycomb, flanked, on one side, by a metallic foil perforated and, on the other side, an unperforated metal sheet, used for their noise attenuation properties, for example as coatings in certain locations in the turbine engine nacelle to absorb at least partially the sound energy of high speed gas flows.

Cependant, de telles structures se sont révélées manquer de solidité lorsqu'on a voulu les utiliser dans des environnements sévères pour réaliser à la fois une atténuation du bruit et une conservation de l'intégrité structurale.However, such structures have been found to lack strength when we wanted to use them in harsh environments to achieve both noise attenuation and preservation of structural integrity.

Par le brevet US N° 3.166.149, on connaít des panneaux du type ci-dessus mais plus sophistiqués en ce qui concerne la nature du revêtement composite à perforations rapporté sur l'une des faces de l'âme en nid d'abeilles. Ce revêtement est constitué, d'une part, d'un treillis en fibres de verre pré-imprégnées de résine polymérisée à des fins de rigidification du treillis avant sa fixation par collage sur l'une des faces du nid d'abeilles. Sur la face externe du treillis est, d'autre part, collée une feuille en matériau poreux, elle-même recouverte d'un revêtement mince, décoratif, perforé, éventuellement amovible, ne participant pas à la rigidité de l'ensemble.By US Patent No. 3,166,149, we know panels of the above type but more sophisticated with regard to the nature of the coating composite with perforations attached to one of the faces of the honeycomb core. This coating consists, on the one hand, of a lattice of prepreg glass fibers of polymerized resin to stiffen the trellis before it fixing by gluing on one side of the honeycomb. On the outside of the on the other hand, a sheet of porous material is glued, itself covered with a thin, decorative, perforated, possibly removable coating, not participating in the rigidity of the whole.

Si un tel panneau est considéré dans ledit brevet comme susceptible d'être utilisé pour réaliser des cloisons, ses rigidité et résistance structurales sont néanmoins insuffisantes pour résister à des charges importantes telles que celles résultant d'un crash. If such a panel is considered in said patent as susceptible to be used to make partitions, its rigidity and structural strength are nevertheless insufficient to withstand heavy loads such as those resulting from a crash.

En outre, les matériaux généralement utilisés pour constituer l'âme en nid d'abeilles et le revêtement non perforé, à savoir un feuillard d'aluminium et une feuille d'aluminium respectivement, conduisent à des structures composites présentant des masses surfaciques trop importantes.In addition, the materials generally used to constitute the nest core bees and the non-perforated coating, namely an aluminum strip and a aluminum foil respectively, lead to composite structures with too large surface masses.

L'invention a pour but de proposer un nouveau type de panneau susceptible en particulier de concilier les exigences les plus sévères en matière de légèreté, de rigidité et résistance mécanique.The invention aims to propose a new type of panel likely in particular to reconcile the most severe requirements in terms of lightness, rigidity and mechanical resistance.

A cet effet, l'invention a pour objet un procédé de fabrication d'un panneau ou analogue à propriétés structurale et acoustique, du type sandwich constitué d'une âme à structure alvéolaire ouverte revêtue sur ses deux faces, caractérisé en ce qu'il consiste :

  • à réaliser une première et une seconde peau par drapage et pressage à chaud dans des conditions de pression et température appropriées d'au moins deux plis de tissu de fibres minérales ou synthétiques imprégnées d'une résine thermoplastique,
  • à réaliser dans l'une des peaux des perforations d'un diamètre de l'ordre de 0,5 à 1,5 mm, avec une proportion de vide à la surface de la peau de l'ordre de 10 à 25%,
  • à appliquer sur l'une des faces de chaque peau, après préparation, un revêtement de colle époxy,
  • à former un sandwich comprenant ladite âme à structure alvéolaire ouverte avec les deux peaux sur ses faces opposées, les revêtements de colle étant en contact avec l'âme,
  • puis à presser à chaud le sandwich à des fins de polymérisation de la colle dans des conditions de température, pression et durée évitant toute obstruction même partielle des perforations de la peau perforée.
To this end, the subject of the invention is a method of manufacturing a panel or the like with structural and acoustic properties, of the sandwich type consisting of a core with open honeycomb structure coated on its two faces, characterized in that it consists of:
  • producing a first and a second skin by draping and hot pressing under conditions of appropriate pressure and temperature of at least two plies of fabric of mineral or synthetic fibers impregnated with a thermoplastic resin,
  • to make perforations in one of the skins with a diameter of the order of 0.5 to 1.5 mm, with a proportion of void on the surface of the skin of the order of 10 to 25%,
  • to be applied to one of the faces of each skin, after preparation, a coating of epoxy adhesive,
  • forming a sandwich comprising said core with open honeycomb structure with the two skins on its opposite faces, the adhesive coatings being in contact with the core,
  • then hot pressing the sandwich for the purpose of polymerizing the adhesive under conditions of temperature, pressure and duration avoiding any obstruction, even partial, of the perforations of the perforated skin.

Avantageusement les deux peaux sont constituées de tissus de fibres de verre imprégnées de résine polyétherimide.Advantageously, the two skins are made of fabrics of fibers of glass impregnated with polyetherimide resin.

Les deux peaux sont constituées d'un même nombre de plis, mais avantageusement peuvent avoir un nombre différent, une telle répartition dissymétrique des peaux de part et d'autre de l'âme centrale permettant de réduire la masse et le coût du panneau, sans nuire à sa planéité, du fait de la fabrication en multiphase du panneau, c'est-à-dire la consolidation séparée des éléments du panneau avant la cuisson de l'ensemble. C'est ainsi que la peau non perforée peut comporter un nombre de plis, trois par exemple, inférieur à celui, quatre par exemple, de la peau perforée, le nombre de plis étant directement lié aux efforts susceptibles de s'appliquer au panneau.The two skins are made up of the same number of folds, but advantageously can have a different number, such a distribution asymmetrical skins on either side of the central core allowing reduce the mass and cost of the panel, without affecting its flatness, due to the multiphase manufacturing of the panel, i.e. separate consolidation of elements of the panel before cooking the whole. This is how the skin non-perforated may have a number of plies, three for example, less than that, for example four, of the perforated skin, the number of folds being directly related to the forces likely to apply to the panel.

Suivant un mode préféré de mise en oeuvre, le revêtement de colle époxy est appliqué sous la forme d'un film mince de très faible masse surfacique et le cycle de polymérisation comporte une montée en température à un premier palier d'une valeur et d'une durée suffisantes pour faire fluer la colle sans pour autant lancer de manière significative sa polymérisation, afin de ne pas obstruer les perforations de la peau, puis à un second palier d'une valeur et d'une durée suffisantes pour réaliser ladite polymérisation.According to a preferred embodiment, the coating of epoxy adhesive is applied in the form of a thin film of very low surface mass and the polymerization cycle involves a rise in temperature to a first level of sufficient value and duration to cause the glue to flow without as much to significantly initiate its polymerization, so as not to obstruct skin perforations, then at a second level of value and duration sufficient to carry out said polymerization.

L'invention a également pour objet le panneau obtenu conformément au procédé ci-dessus, un tel panneau étant par exemple dimensionné, conformé et pourvu d'éléments de bordures, d'inserts et autres aménagements pour la constitution d'éléments de cloison de fuselage d'aéronefs. De tels éléments de cloison se sont révélés présenter d'excellentes propriétés d'atténuation acoustique pour des fréquences supérieures à 500 Hz et de résistance à des charges importantes appliquées normalement à la cloison. C'est ainsi, par exemple, qu'un panneau selon l'invention d'une surface de 1,5 m2 a résisté à des efforts de l'ordre de 900 daN.The subject of the invention is also the panel obtained in accordance with the above process, such a panel being for example dimensioned, shaped and provided with border elements, inserts and other arrangements for the construction of fuselage bulkhead elements. aircraft. Such partition elements have been found to have excellent acoustic attenuation properties for frequencies above 500 Hz and resistance to heavy loads normally applied to the partition. Thus, for example, a panel according to the invention with a surface of 1.5 m 2 withstood forces of the order of 900 daN.

De plus, notamment la face perforée d'une telle cloison, peut être facilement traitée esthétiquement, soit par teinture dans la masse de la résine de la peau, avec un aspect de surface en relief, par exemple un granité, obtenu au moulage, soit par thermogainage d'un revêtement tel qu'un film décor perforé, soit par application d'un tel revêtement ou d'un textile acoustiquement transparent.In addition, in particular the perforated face of such a partition, can be easily treated aesthetically, either by dyeing the bulk of the resin the skin, with a relief surface appearance, for example a granita, obtained at molding, either by thermo-sheathing a coating such as a perforated decorative film, either by applying such a coating or acoustically textile transparent.

D'autres caractéristiques et avantages ressortiront de la description qui va suivre d'un mode de réalisation d'un panneau selon l'invention, description donnée à titre d'exemple uniquement et en regard du dessin annexé sur lequel :

  • Figure 1 est une vue en coupe et en éclaté schématique d'une structure de panneau selon l'invention ;
  • Figure 2 est une vue en perspective partielle et en arraché d'un panneau réalisé, du type illustré en figure 1, et
  • Figure 3 est une courbe illustrant un cycle de cuisson préférentiel du panneau.
Other characteristics and advantages will emerge from the following description of an embodiment of a panel according to the invention, description given by way of example only and with reference to the appended drawing in which:
  • Figure 1 is a schematic sectional and exploded view of a panel structure according to the invention;
  • FIG. 2 is a partial perspective view and a cutaway view of a panel produced, of the type illustrated in FIG. 1, and
  • Figure 3 is a curve illustrating a preferred cooking cycle of the panel.

Sur la figure 1 on a schématisé un panneau sandwich vu sur la tranche et comprenant une âme centrale à structure alvéolaire ouverte 1, flanquée de part et d'autre d'une peau, à savoir une peau inférieure multiplis 2 et une peau supérieure multiplis 3.In Figure 1 we have schematically shown a sandwich panel seen on the edge and comprising a central core with an open honeycomb structure 1, flanked by and on the other side of a skin, namely a 2-ply lower skin and a skin upper multiply 3.

Conformément à l'invention, chaque peau 2,3 est constituée de plusieurs plis formés chacun d'un tissu de fibres synthétiques ou minérales imprégnées d'une résine thermoplastique et chaque peau est consolidée avant assemblage du sandwich. A cet effet, un tissu de fibres pré-imprégnées est drapé suivant plusieurs couches ou plis superposés sur une surface plane appropriée. L'ensemble est compacté à température appropriée suivant la nature des fibres et de la résine en sorte d'obtenir une peau rigide autoportante. Une telle opération, appelée communément consolidation, est en soi bien connue de l'homme du métier et il n'est pas nécessaire de donner plus amples détails.According to the invention, each skin 2,3 is made up of several pleats each formed from a fabric of impregnated synthetic or mineral fibers of a thermoplastic resin and each skin is consolidated before assembly sandwich. To this end, a fabric of prepreg fibers is draped according to several layers or folds superimposed on a suitable flat surface. The assembly is compacted at an appropriate temperature according to the nature of the fibers and resin so as to obtain a rigid self-supporting skin. Such a operation, commonly called consolidation, is in itself well known to skilled in the art and there is no need to give further details.

Toutefois, préférentiellement, on utilisera des fibres de verre du type E imprégnées à raison de 30 à 35% de résine polyétherimide. Plus précisément encore, comme fibres et résine particulièrement appropriées, on peut citer, d'une part, les tissus de fibres de verre E connues dans le commerce sous la désignation "7781" et, d'autre part, la résine polyétherimide dénommée commercialement "ULTEM"® fabriquée par la Société GENERAL ELECTRIC.However, preferably, type E glass fibers will be used impregnated with 30 to 35% polyetherimide resin. More precisely still, as particularly suitable fibers and resin, there may be mentioned, on the one hand, the E glass fiber fabrics known in the trade under the designation "7781" and, on the other hand, the polyetherimide resin called commercially "ULTEM" ® manufactured by GENERAL ELECTRIC.

L'une des peaux, en l'occurrence la peau supérieure 3, les termes "supérieure" et "inférieure" n'ayant pas en fait de signification pratique puisque le sandwich final peut être utilisé dans n'importe quelle position dans l'espace, est en outre, conformément à l'invention, muni, après consolidation, d'une pluralité de trous identiques 4 traversant normalement l'épaisseur de la peau.One of the skins, in this case the upper skin 3, the terms "superior" and "inferior" having in fact no practical significance since the final sandwich can be used in any position in space, is further, in accordance with the invention, provided, after consolidation, with a plurality of identical holes 4 normally passing through the thickness of the skin.

De préférence, la proportion, en surface totale de la peau 3, des vides ou trous 4 est de l'ordre de 10 à 25% et le diamètre des trous 4 est de l'ordre de 0,5 à 1,5 mm et plus particulièrement encore de 1 mm pour un pourcentage des vides de l'ordre de 23%. Il est par ailleurs préférable que le diamètre des trous soit supérieur ou égal à l'épaisseur de la peau.Preferably, the proportion, in total area of the skin 3, of the voids or holes 4 is around 10 to 25% and the diameter of holes 4 is around 0.5 to 1.5 mm and more particularly still 1 mm for a percentage of voids of the order of 23%. It is also preferable that the diameter of the holes is greater than or equal to the thickness of the skin.

Par ailleurs, la distribution des trous est uniforme sur toute la surface.Furthermore, the distribution of the holes is uniform over the entire surface.

Les peaux 2 et 3 sont avantageusement réalisées à partir des mêmes fibres et résine et, suivant une autre caractéristique de l'invention, comportent un nombre de plis différent, celui de la peau perforée 3 étant par exemple supérieur à celui de la peau non perforée 2.The skins 2 and 3 are advantageously made from the same fibers and resin and, according to another characteristic of the invention, comprise a different number of folds, that of the perforated skin 3 being for example higher than that of unperforated skin 2.

A titre d'exemple, la peau non perforée 2 comporte trois plis : 2a, 2b, 2c et la peau perforée 3 en comporte quatre : 3a, 3b, 3c, 3d.For example, the non-perforated skin 2 has three folds: 2a, 2b, 2c and the perforated skin 3 has four: 3a, 3b, 3c, 3d.

Une fois les peaux 2,3 consolidées, on procède à leur assemblage, par collage, à l'âme 1. Celle-ci est, d'une manière générale, une structure à alvéoles ouverts suivant un axe perpendiculaire au plan médian de l'âme et, en particulier est constitué d'une structure en nid d'abeilles, par exemple réalisée en un papier de fibres aramides tel que celui dénommé commercialement "NOMEX"®.Once the skins 2,3 have been consolidated, they are assembled, by bonding, to the core 1. This is, in general, a honeycomb structure open along an axis perpendicular to the median plane of the soul and, in particular consists of a honeycomb structure, for example made of paper aramid fibers such as that known commercially as "NOMEX" ®.

L'une des faces de chaque peau 2, 3 est revêtue d'une colle époxy appropriée, appliquée de façon la plus régulière possible. Par exemple, la colle sera appliquée par pulvérisation, mais, de préférence, elle sera constituée d'un film mince de très faible masse surfacique, de l'ordre de 70 g/m2 par exemple. Plus particulièrement encore, le film adhésif dénommé SCOTCH-WELD® AF 163-2U fabriqué par la Société 3M convient remarquablement. Il est à noter que cette colle est auto-extinguible et que, d'une manière préférentielle, on utilisera une colle ayant cette propriété.One of the faces of each skin 2, 3 is coated with an appropriate epoxy adhesive, applied as evenly as possible. For example, the adhesive will be applied by spraying, but preferably it will consist of a thin film of very low surface mass, of the order of 70 g / m 2 for example. More particularly still, the adhesive film called SCOTCH-WELD® AF 163-2U manufactured by the company 3M is remarkably suitable. It should be noted that this adhesive is self-extinguishing and that, preferably, an adhesive having this property will be used.

Ensuite, les parties 1,2,3 du sandwich sont superposées sur un plateau de presse chauffante et soumises à un cycle de cuisson à des fins de polymérisation de la colle.Then, the 1,2,3 parts of the sandwich are superimposed on a tray heating press and subjected to a cooking cycle for the purpose of adhesive polymerization.

Conformément à l'invention et dans le cas de l'utilisation du film d'adhésif de la Société 3M, le cycle de polymérisation est opéré à pression constante, de l'ordre de 1 bar ou un peu plus, et en amenant la température à un premier palier 5, aux environs de 80°C ,puis à un second palier 6, aux environs de 130°C, avant de redescendre à une température de l'ordre de 50°C à laquelle la pression est supprimée et le panneau démoulé. According to the invention and in the case of the use of the adhesive film from 3M, the polymerization cycle is operated at constant pressure, around 1 bar or a little more, and bringing the temperature to a first level 5, around 80 ° C, then at a second level 6, around 130 ° C, before going down to a temperature of the order of 50 ° C at which the pressure is removed and the panel is demolded.

La figure 3 illustre un cycle du type ci-dessus, au cours duquel le palier 5 de température à 80°C est maintenu pendant 30 minutes et le palier 6 à 130°C pendant 60 minutes, une pression de 1,2 bar étant maintenue pendant tout le cycle.FIG. 3 illustrates a cycle of the above type, during which the bearing 5 temperature at 80 ° C is maintained for 30 minutes and the level 6 at 130 ° C for 60 minutes, a pressure of 1.2 bar being maintained throughout cycle.

La température du premier palier 5 et la durée de celui-ci sont déterminées de façon à être suffisantes pour faire fluer la colle sans pour autant et de manière significative lancer la phase de polymérisation.The temperature of the first stage 5 and the duration thereof determined to be sufficient to cause the glue to flow without and significantly initiate the polymerization phase.

Au cours de ce premier palier 5, la colle va se liquéfier et au niveau des trous de la peau perforée le film va se rompre et le matériau de la colle va s'agglutiner en formant un ménisque à l'interface peau 3 - âme 1 et sur le pourtour de chaque trou 4.During this first level 5, the glue will liquefy and at the level of the perforated skin holes the film will break and the glue material will clump together to form a meniscus at the skin 3 - core 1 interface and on the around each hole 4.

Quant au second palier de température 6, il est effectué à une température et pendant une durée suffisantes pour permettre une polymérisation totale.As for the second temperature level 6, it is carried out at a temperature and for a sufficient time to allow polymerization total.

Dans le cas de l'application de la colle par pulvérisation, les trous 4 ne seront pas bouchés et le cycle de polymérisation est opéré à la manière habituelle et ne comporte pas les deux paliers de température de la figure 3.In the case of spray adhesive application, the holes 4 do not will not be blocked and the polymerization cycle is operated in the manner usual and does not include the two temperature levels of Figure 3.

La figure 2 illustre un panneau réalisé selon le schéma d'empilage de la figure 1.FIG. 2 illustrates a panel produced according to the stacking diagram of the figure 1.

Dans la pratique on réalisera directement le panneau aux formes et dimensions de la cloison ou élément de cloison à obtenir, par exemple pour séparer les zones soute et passager d'un aéronef type turbopropulseur.In practice, the panel will be directly shaped and dimensions of the partition or partition element to be obtained, for example for separate the hold and passenger areas of a turboprop aircraft.

A cet effet, après consolidation des peaux, dont le nombre de plis de chacune sera déterminé en fonction de la nature et l'emplacement de la cloison à réaliser, on effectuera un détourage des peaux au laser, puis éventuellement un pliage et un soyage. De même, le nid d'abeilles sera usiné, soyé et détouré.To this end, after consolidation of the skins, the number of folds of each will be determined according to the nature and location of the partition to be carried out, a laser clipping of the skins will be carried out, then possibly folding and sinking. Likewise, the honeycomb will be machined, crimped and cut.

Les faces à coller des peaux seront poncées, dépoussiérées, dégraissées et enduites ou revêtues d'un film d'adhésif époxy approprié.The faces to be glued on the skins will be sanded, dusted, degreased and coated or coated with a suitable epoxy adhesive film.

Les trois éléments constitutifs du sandwich seront ensuite mis en place dans un moule, et complétés par des éléments de bordure, de renfort, des inserts etc... The three components of the sandwich will then be put in place in a mold, and supplemented by border elements, reinforcement, inserts etc ...

Le moule enfin sera alors placé entre les plateaux d'une presse chauffante pour y subir ledit cycle de polymérisation de la colle ou adhésif.The mold will then be placed between the plates of a heating press to undergo said polymerization cycle of the glue or adhesive.

Les panneaux, cloisons ou éléments de cloison ainsi obtenus peuvent être plats ou cintrés ou présenter des parties planes formant un angle entre elles.The panels, partitions or partition elements thus obtained can be flat or curved or have flat parts forming an angle between them.

A titre d'exemple, le procédé de l'invention permet d'obtenir des peaux consolidées, prêtes à l'assemblage, multiplis, chaque pli ayant une épaisseur de 0,25mm et une masse surfacique de 450 g/m2 pour un pli non perforé et de 350 g/m2 pour un pli perforé, les tissus de fibres étant constitués de verre E, d'une masse surfacique de 300 g/m2, d'une épaisseur de 20/100 de millimètre, d'armure satin 8, avec un nombre de fils de chaíne de 22 et de fils de trame de 20, cependant que la résine est du type polyétherimide.By way of example, the method of the invention makes it possible to obtain consolidated skins, ready for assembly, plywood, each ply having a thickness of 0.25mm and a surface mass of 450 g / m 2 for a ply non-perforated and 350 g / m 2 for a perforated ply, the fiber fabrics being made of E glass, a surface mass of 300 g / m 2 , with a thickness of 20/100 of a millimeter, weave satin 8, with a number of warp threads of 22 and weft threads of 20, while the resin is of the polyetherimide type.

La consolidation des peaux avant assemblage, conformément à l'invention, permet de réaliser des panneaux dissymétriques présentant une face renforcée à nombre de plis supérieur à celui de l'autre face.Consolidation of the skins before assembly, in accordance with the invention makes it possible to produce asymmetrical panels having one face reinforced with more folds than the other side.

Si l'on avait employé la technique habituelle de réalisation en co-cuisson de ce panneau sandwich, il aurait fallu disposer autant de plis de chaque côté du nid d'abeilles pour éviter toute déformation ou voilage du panneau en cours de polymérisation. Ceci aurait conduit à placer inutilement un pli supplémentaire sur l'une des faces.If we had used the usual technique of co-cooking of this sandwich panel, there should have been as many folds on each side honeycomb to prevent any deformation or buckling of the panel in progress polymerization. This would have unnecessarily placed an additional fold on one of the faces.

La technique de l'invention permet d'enlever un tel pli sur la face moins sollicitée, ce qui abaisse la masse de l'ensemble et le coût. En outre, les surfaces du panneau sandwich demeurent parfaitement planes malgré la répartition dissymétrique des peaux.The technique of the invention makes it possible to remove such a fold on the less face solicited, which lowers the mass of the assembly and the cost. In addition, sandwich panel surfaces remain perfectly flat despite the asymmetrical distribution of skins.

D'une manière générale, l'épaisseur de l'âme 1 est directement liée au spectre de fréquences que l'on désire atténuer. Pour les fréquences plus particulièrement visées dans les applications notamment aux cloisons d'avions du type turbopropulseur, c'est-à-dire des fréquences dans la gamme 1200 à 2000 Hz, l'épaisseur de l'âme 1 sera typiquement de l'ordre de vingt millimètres.In general, the thickness of the core 1 is directly linked to the frequency spectrum that one wishes to attenuate. For higher frequencies particularly targeted in applications in particular to aircraft partitions turboprop type, i.e. frequencies in the 1200 to 2000 Hz, the thickness of the core 1 will typically be of the order of twenty millimeters.

Quant au diamètre des trous 4, il est lié assez étroitement au pourcentage de vide dans la peau perforée, étant entendu par ailleurs que le couple de ces deux paramètres (diamètre des trous et pourcentage de vide) pourra évoluer en fonction des caractéristiques ou propriétés acoustiques des éventuels éléments de revêtements décoratifs dont pourrait être munie la peau perforée.As for the diameter of the holes 4, it is fairly closely related to the percentage vacuum in the perforated skin, it being understood that the pair of these two parameters (diameter of the holes and percentage of vacuum) can change in function of the acoustic characteristics or properties of any elements decorative coverings which could be provided on the perforated skin.

En effet, outre les propriétés structurales, d'atténuation acoustique et de légèreté des panneaux ou cloisons obtenus conformément à l'invention, il faut également noter leur aptitude à une décoration facile et économique, soit par l'utilisation pour les peaux d'une résine teintée dans la masse, soit par la constitution sur la face visible de la peau d'un état de surface esthétique, par exemple aspect granité, communiqué par le moule sur lequel sont drapés les plis, soit encore par revêtement, par exemple de la peau perforée, par thermogainage d'un film décor perforé ou collage d'un tel film ou d'un revêtement textile acoustiquement transparent.In fact, in addition to the structural properties, acoustic attenuation and lightness of the panels or partitions obtained in accordance with the invention, it is necessary also note their ability to decorate easily and economically, either by the use for the skins of a resin dyed in the mass, either by the constitution on the visible face of the skin of an aesthetic surface state, by example granite aspect, communicated by the mold on which the folds, or again by coating, for example of the perforated skin, by thermogainage of a perforated decorative film or bonding of such a film or of a acoustically transparent textile covering.

Enfin, les panneaux, cloisons ou autres produits obtenus conformément au procédé de l'invention, satisfont à la norme FAR 25 § 853 (critères de Feu/Fumée/Toxicité) applicable aux avions commerciaux, notamment du fait du choix pour les peaux d'une résine polyétherimide.Finally, panels, partitions or other products obtained in accordance to the process of the invention, comply with standard FAR 25 § 853 (criteria for Fire / Smoke / Toxicity) applicable to commercial aircraft, in particular due to the choice for the skins of a polyetherimide resin.

Claims (16)

  1. Method of manufacturing a panel or the like with structural and acoustic properties of the sandwich type consisting of a core with an open alveolar structure (1) clad on its two faces, characterised in that it comprises:
    producing first and second skins (2, 3) by the corrugation and hot pressing, under suitable pressure and temperature conditions, of at least two plies of cloth of mineral or synthetic fibres impregnated with a thermoplastic resin,
    producing, in one of the skins (2, 3), perforations (4) with a diameter of the order of 0.5 to 1.5 mm, with a proportion of void on the surface of the skin of the order of 10 to 25%,
    applying to one of the faces of each skin, after preparation, a covering of epoxy glue,
    forming a sandwich comprising said core with open alveolar structure (1) with the two skins (2, 3) on its opposite faces, the coatings of glue being in contact with the core,
    then hot pressing the sandwich for the purpose of polymerisation of the glue under conditions of temperature, pressure and duration preventing any obstruction, even partial, of the perforations in the perforated skin (3).
  2. Method according to Claim 1, characterised in that the skins (2, 3)consist of cloths of glass fibres impregnated with polyetherimide resin.
  3. Method according to Claim 1 or 2, characterised in that the two skins (2, 3) have different numbers of plies.
  4. Method according to Claims 1 to 3, characterised in that the coating of glue is a thin film with a very low mass per surface area.
  5. Method according to Claim 4, characterised in that the glue is a self-extinguishing glue.
  6. Method according to Claim 4 or 5, characterised in that the film of glue is the film known as SCOTCH-WELD® AF 163-2U from the 3M Company.
  7. Method according to one of Claims 4 to 6, characterised in that the polymerisation step is effected in accordance with a cycle including a rise in temperature to a first level with a sufficient value and duration to cause the glue to flow without significantly initiating its polymerisation, and then to a second level with a sufficient value and duration to effect said polymerisation.
  8. Method according to Claim 7, characterised in that said first temperature level is maintained for a period of the order of 30 minutes and said second temperature level is maintained for a period of the order of 60 minutes.
  9. Panel or the like obtained in accordance with the method according to any one of Claims 1 to 8.
  10. Panel according to Claim 9, characterised in that the core with a alveolar structure is a honeycomb (1).
  11. Panel according to Claim 9 or 10, characterised in that it comprises an unperforated skin (2) with three plies and a perforated skin (3) with four plies, each ply having a thickness of 0.25 mm and consisting of E type glass fibres impregnated with polyetherimide resin.
  12. Panel according to one of Claims 9 to 11, characterised in that the perforated skin (3) comprises perforations with a diameter of the order of 1 mm, the percentage of voids in the skin being the order of 23%.
  13. Panel according to one of Claims 9 to 12, characterised in that the resin in at least one of the skins (2, 3) is coloured in its mass.
  14. Panel according to one of Claims 9 to 12, characterised in that the visible face of at least one of the skins (2, 3) is covered by heat-sheathing with a decorated film, perforated or otherwise.
  15. Panel according to one of Claims 9 to 12, characterised in that the visible face of at least one of the skins (2, 3) is covered with a textile, acoustically transparent or otherwise.
  16. Panel according to one of Claims 9 to 12, characterised in that the visible face of at least one of the skins (2, 3) has a surface appearance in relief, notably a granite.
EP96450012A 1995-06-08 1996-06-05 Method of fabrication of a plate or the like with structural and acoustic features and plate obtained this way Expired - Lifetime EP0747547B1 (en)

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FR9507020 1995-06-08
FR9507020A FR2735166B1 (en) 1995-06-08 1995-06-08 METHOD FOR MANUFACTURING A PANEL OR THE LIKE WITH STRUCTURAL AND ACOUSTIC PROPERTIES AND PANEL SO OBTAINED

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EP0747547B1 true EP0747547B1 (en) 2000-04-19

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EP (1) EP0747547B1 (en)
CN (1) CN1078844C (en)
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DE (1) DE69607783T2 (en)
ES (1) ES2147908T3 (en)
FR (1) FR2735166B1 (en)

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FR2735166A1 (en) 1996-12-13
FR2735166B1 (en) 1997-08-29
CA2178148A1 (en) 1996-12-09
CN1141866A (en) 1997-02-05
CN1078844C (en) 2002-02-06
ES2147908T3 (en) 2000-10-01
EP0747547A1 (en) 1996-12-11
CA2178148C (en) 2008-01-29
DE69607783D1 (en) 2000-05-25
DE69607783T2 (en) 2000-11-23
US5888610A (en) 1999-03-30

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