EP4107061A1

EP4107061A1 - Method for manufacturing an aerodynamic aircraft structure and aerodynamic aircraft structure thus obtained

Info

Publication number: EP4107061A1
Application number: EP21706530.9A
Authority: EP
Inventors: Benjamin TRARIEUX; Harleen Kaur; Stéphane DAURE; Brice Albert
Original assignee: Airbus Operations SAS
Current assignee: Airbus Operations SAS
Priority date: 2020-02-18
Filing date: 2021-02-16
Publication date: 2022-12-28
Also published as: FR3107254A1; US20230062638A1; WO2021165268A1; CN115103799A

Abstract

The invention relates to a method for manufacturing an aerodynamic structure (34) comprising a first panel (42) having an aerodynamic face (F34) as well as a second reinforced panel (44), characterised in that the manufacturing method comprises a step of stamping the second panel (44) to obtain at least one raised shape (46) which is recessed on the second face (44.2), as well as a step of joining the first and second panels (42, 44) by pressing them against each other outside the raised shape(s) (46). The invention also relates to an aerodynamic structure obtained using said method.

Description

A method of manufacturing an aircraft aerodynamic structure and an aircraft aerodynamic structure thus obtained

[0001] The present application relates to a method of manufacturing an aerodynamic structure of an aircraft, mobile or fixed, as well as to an aerodynamic structure of an aircraft, mobile or fixed, thus obtained.

According to an embodiment known from document EP2862798, visible in Figures 2 and 3, a mobile aerodynamic structure 10 such as an airbrake for example, comprises first and second panels 12, 14 connected by a plurality ribs 16 to form a box structure. The mobile aerodynamic structure 10 comprises several connecting elements 18 forming part of an articulation as well as a connecting element 20 configured to connect an actuator to the mobile aerodynamic structure 10. The ribs 16 are arranged to ensure optimum transmission of forces. between the connecting elements 18, 20 and the first or second panel 12, 14 in contact with an aerodynamic flow in operation.

According to a first manufacturing process, the first and second panels 12, 14 and the ribs 16 are produced independently of each other and then are assembled. This first production process is not satisfactory because it requires managing a large number of parts, which tends to increase the duration and the manufacturing costs.

According to a second manufacturing process, the first panel 12 and the ribs 16 are made in one piece from a block of material machined to hollow out the cells between the ribs 16. This second manufacturing process does not is not satisfactory because it generates a lot of waste. In addition, it leads to significant costs and manufacturing time for each structure.

[0005] According to another drawback, the mobile aerodynamic structure obtained from the first and second manufacturing methods of the prior art has a relatively large mass.

[0006] The present invention aims to remedy all or part of the drawbacks of the prior art.

[0007] To this end, the invention relates to a method of manufacturing an aerodynamic structure comprising a first panel having first and second faces, the first face forming an aerodynamic face, as well as a second reinforced panel having first and second sides, the second side of the second panel being oriented towards the second face of the first panel. According to the invention, the manufacturing method comprises a step of shaping the second panel, during which the second panel is stamped to obtain at least one relief shape, recessed at the level of the second face, as well as a step junction of the first and second panels by pressing their second face against each other outside the (or more) shape (s) in relief.

[0008] The method of the invention makes it possible to obtain an aerodynamic structure from a small number of parts, which tends to reduce the duration and costs of manufacture. In addition, the fact of creating ribs on the second panel by stamping allows, with equal mechanical characteristics, to reduce the mass of the aerodynamic structure compared to the prior art.

[0009] According to other characteristics taken alone or in combination: a. before the joining step, the method comprises a step of inserting an intermediate panel between the first and second panels, the intermediate panel comprising first and second faces, the first face being oriented towards the second face of the first panel and the second face being oriented towards the second face of the second panel. The insertion of an intermediate panel allows to have a second generic panel for different aerodynamic structures, while the first panel is specific to an aerodynamic structure; b. during the joining step, the second face of the second panel and the second face of the intermediate panel are pressed against each other outside of the shape (s) in relief, and the second face of the first panel and the first face of the intermediate panel are pressed against each other; vs. during the joining step, the first and second panels are connected by welding; d. the manufacturing process comprises, before the step of shaping the second panel, a step of shaping the first and second panels identically according to a desired aerodynamic profile; e. after the step of shaping the second panel, the manufacturing process comprises a step of fixing at least one connecting element on the second panel at the level of the relief shape. The aerodynamic structure thus obtained is therefore a mobile aerodynamic structure.

The invention also relates to an aerodynamic structure comprising a first panel having first and second faces, the first face forming an aerodynamic face, and a second reinforced panel having first and second faces, the second face of the second panel being oriented towards the second face of the first panel, the second panel comprising at least one relief shape, recessed at the level of the second face, the second faces of the first and second panels being interconnected apart from the relief shape (s). According to the invention, the aerodynamic structure also comprises an intermediate panel arranged between the first and second panels.

[0011] The presence of an intermediate panel between the first and second panels allows to have a second generic panel for different aerodynamic structures, while the first panel and the intermediate panel are specific to an aerodynamic structure.

[0012] According to another characteristic, the aerodynamic structure comprises first and second longitudinal edges, first and second lateral edges as well as at least one main or secondary connecting element positioned near the first longitudinal edge. In addition, the relief shape comprises at least one main cavity to which is connected at least one of the main and secondary connecting elements. This aerodynamic structure is therefore a mobile aerodynamic structure.

[0013] According to another characteristic, the main cavity extends parallel to the first longitudinal edge, over a length greater than or equal to at least one third of a distance separating the first and second lateral edges.

[0014] According to another characteristic, the main cavity has a maximum depth in line with a main connecting element, this depth decreasing as it approaches the first and second lateral edges.

According to another characteristic, the relief shape comprises at least one branch which extends in the direction of at least one of the first and second longitudinal and lateral edges, from a first end connected to the main cavity up to a second end.

[0016] According to another characteristic, the intermediate panel comprises at least one branch of shape substantially identical to a shape of the branch of the relief shape or to a peripheral shape of part of the cavity.

[0017] According to another characteristic, the second end of each branch of the relief shape is distant from the first and second longitudinal and lateral edges.

[0018] According to another characteristic, each branch of the relief form comprises a section which decreases between the first end and the second end. According to another characteristic, each connecting element comprises at least one plate having an edge which matches the shape of the second panel to the right of a main cavity.

[0020] According to another characteristic, the edge is connected to the second panel outside the relief shape as well as to a bottom and a side wall of the main cavity.

[0021] According to another characteristic, the main cavity or at least one branch of the relief form comprises a reinforcing rib.

[0022] According to another characteristic, the aerodynamic structure comprises at least one plate arranged between the main or secondary connecting element and the first panel. More precisely, according to one characteristic, the aerodynamic structure comprises at least one plate arranged between the main or secondary connecting element and the second panel. According to another characteristic, the aerodynamic structure comprises at least one plate arranged between the second panel and the first panel. According to another characteristic, the aerodynamic structure comprises at least one plate arranged between the second panel and the intermediate panel.

According to another characteristic, the second face of the first panel has an extra thickness, and the second face of the second panel is conformed to said extra thickness. This extra thickness of the first panel makes it possible to integrate an aerodynamic function into the second face of the second panel.

[0024] The subject of the invention is also an aircraft comprising at least one aerodynamic structure according to one of the preceding characteristics.

Other characteristics and advantages will emerge from the description of the invention which follows, description given by way of example only, with reference to the accompanying drawings, among which:

[0026] Figure 1 is a top view of an aircraft,

[0027] Figure 2 is a side view of a mobile aerodynamic structure illustrating an embodiment of the prior art,

[0028] Figure 3 is a perspective view of a first part of the mobile aerodynamic structure visible in Figure 2,

FIG. 4 is a diagram of the different parts of a mobile aerodynamic structure before and after an assembly step illustrating an embodiment of the invention, [0030] Figure 5 is a perspective view, from a first angle of view, of a panel of a mobile aerodynamic structure illustrating an embodiment of the invention, [0031] Figure 6 is a perspective view , from a second angle of view, of the panel visible in FIG. 5,

[0032] Figure 7 is a perspective view, from a first angle of view, of a panel of an aerodynamic structure illustrating another embodiment of the invention, [0033] Figure 8 is a partial view of top of a panel of an aerodynamic structure illustrating another embodiment of the invention,

Figure 9 is a section along the line IX-IX of Figure 8,

Figure 10 is a section along the line X-X of Figure 8,

[0036] Figure 11 is a perspective view of a mobile aerodynamic structure illustrating an embodiment of the invention,

Figure 12 is a section along the line XII-XII of Figure 11,

[0038] Figure 13 is a perspective view of a mobile aerodynamic structure illustrating another embodiment of the invention,

Figure 14 is a front view of the mobile aerodynamic structure visible in Figure 13,

[0040] Figure 15 is a perspective view of a mobile aerodynamic structure illustrating another embodiment of the invention,

Figure 16 is a front view of the mobile aerodynamic structure visible in Figure 15,

[0042] Figure 17 is a top view of a panel of an aerodynamic structure illustrating an embodiment of the invention,

Figure 18 is an enlarged view of box E of Figure 17,

[0044] Figure 19 is a top view of a panel of an aerodynamic structure illustrating an embodiment of the invention,

[0045] Figure 20 is a perspective view of an aerodynamic structure illustrating another embodiment of the invention,

[0046] Figure 21 is a perspective view of a panel of an aerodynamic structure illustrating an embodiment of the invention,

Figure 22 is a section along the line XXII-XXII of Figure 21,

Figure 23 is a sectional and perspective view of a panel of an aerodynamic structure illustrating an embodiment of the invention, Figure 24 is a perspective view of a panel of an aerodynamic structure illustrating another embodiment of the invention, and

[0050] Figure 25 is a sectional and perspective view of an aerodynamic structure illustrating an embodiment of the invention.

According to one embodiment visible in Figure 1, an aircraft comprises two wings 30 arranged on either side of the fuselage 32 and each equipped with five movable flaps 34.1, 34.2, called airbrakes.

[0052] Of course, the invention is not limited to speed brakes. More broadly, the invention relates to all mobile aerodynamic structures 34 having at least one aerodynamic face F34 in contact with a flow of air circulating around the aircraft when the latter is moving. For example, the movable aerodynamic structure is an aircraft hatch.

The invention also relates to all fixed aerodynamic structures having at least one aerodynamic face in contact with a flow of air circulating around the aircraft when the latter is moving.

In the remainder of the description, the invention is mainly described for a mobile aerodynamic structure 34. The characteristics of the mobile aerodynamic structure 34 described also apply to a fixed aerodynamic structure.

In operation, each mobile aerodynamic structure 34 is connected by at least one articulation 36 (symbolized by an axis in FIG. 4) to the rest of the aircraft and its position is controlled by at least one actuator 38 (shown so schematic in Figure 4). To this end, the mobile aerodynamic structure 34 comprises at least one main connecting element 40 to which G actuator 38 is connected and / or at least one secondary connecting element 41 forming part of the articulation 36.

The aerodynamic structure 34 comprises a first panel 42 having a first face 42.1 forming the aerodynamic face F34 and a second face 42.2 opposite the first face 42.1 as well as a second panel 44, reinforced, having first and second faces 44.1 , 44.2, the second face 44.2 being oriented towards the second face 42.2 of the first panel 42, the first and second panels 42, 44 being connected to one another to form the aerodynamic structure 34. The first panel 42 is shaped according to a desired aerodynamic profile. It can be flat or slightly curved. This first panel 42 can be metallic or made of a composite material.

[0058] According to one characteristic of the invention, the second panel 44 has at least one relief shape 46 obtained by stamping, forming at least one rib. When the first and second panels 42, 44 are joined, the relief shape 46 forms a box structure.

The second panel 44 is made from at least one sheet or metal plate or a long-fiber thermoplastic composite material having a substantially constant thickness before stamping. The second panel 44 is stamped so that the relief shape 46 is hollow at the level of the second face 44.2, oriented towards the second face 42.2 of the first panel 42 and protruding at the level of the first face 44.1.

When the second panel 44 is made of metallic material, the second panel 44 is stamped, or stamped, so as to form the relief shape 46. When the second panel 44 is made of thermoplastic composite material, the second panel 44 is stamped to form the relief shape 46.

According to one embodiment, the second panel 44 is flat or slightly curved outside the relief shape (or shapes) 46. Outside the relief shape (s) 46, the second panel 44 is shaped like the first panel 42. Thus, apart from the shape (s) in relief 46, the first and second panels 42, 44 are closely pressed against one another.

[0062] According to one embodiment, the first and second panels 42, 44 are interconnected by welding, gluing, by co-firing or any other assembly process. For example, the first and second panels 42, 44 are welded using an electron beam. When the first and second panels 42, 44 are joined together by welding, the first and second panels are made of metallic material or of composite material.

The geometry and the arrangement of the relief shapes 46 will be determined as a function of the stresses applied to the aerodynamic structure.

According to one configuration, the aerodynamic structure 34 has an approximately rectangular shape and comprises first and second longitudinal edges 48.1, 48.2 approximately parallel to each other as well as first and second lateral edges 50.1, 50.2 approximately parallel to each other. In Operation, for a mobile aerodynamic structure 34, the first longitudinal edge 48.1 is positioned parallel to and close to the articulation 36 and the first lateral edge 50.1 is closer to the fuselage 32 than the second lateral edge 50.2.

[0065] According to one embodiment, the main connecting element 40 is positioned near the first longitudinal edge 48.1. It is not positioned equidistant from the first and second side edges 50.1, 50.2 but slightly offset towards the second side edge 50.2. The secondary connecting elements 41 are arranged near the first longitudinal edge 48.1, on either side of the main connecting element 40. According to one embodiment visible in FIGS. 4 and 13 to 16, the aerodynamic structure 34 mobile comprises two secondary connecting elements 41 arranged on either side of the main connecting element 40. According to another embodiment visible in FIGS. 5 and 6, the mobile aerodynamic structure 34 comprises four secondary connecting elements 41 , two on either side of the main connecting element 40.

Each relief shape 46 comprises at least one main cavity 52 having a bottom 54.1 and side walls 54.2. According to one configuration, the side walls 54.2 of the main cavity 52 describe a square or a rectangle with rounded corners.

According to embodiments visible in Figures 5 to 7, the main cavity 52 forms a longitudinal rib, approximately parallel to the first longitudinal edge 48.1, which extends over a length greater than or equal to at least one third of the length of the aerodynamic structure, the length corresponding to the distance between the first and second lateral edges 50.1, 50.2.

According to these embodiments, the main connecting element 40 and at least some secondary connecting elements 41 are connected to the main cavity 52.

According to one configuration, the main cavity 52 has a depth P (distance between the bottom 54.1 and the first panel 42 when it is connected to the second panel 44) which is not constant. Thus, the main cavity 52 has a maximum depth at the level of the implantation of the main connecting element 40, this depth decreasing as it approaches the first and second side edges 50.1, 50.2.

The depth can vary in stages, as illustrated in Figures 5 to 8, or continuously. According to the embodiments visible in Figures 5 to 7, the main cavity 52 has a maximum depth to the right of the implantation area of the main connecting element 40 and a depth less than the maximum depth to the right of the implantation zones of the secondary connecting elements 41. The main cavity 52 has a width (dimension taken perpendicular to the first longitudinal edge 48.1) constant over its entire length (dimension taken parallel to the first longitudinal edge 48.1). As a variant, the main cavity 52 has an evolving width, this width being maximum in line with the implantation zone of the main connecting element 40 and decreasing as it approaches the first and second lateral edges 50.1, 50.2. This change in width can be done in stages or continuously. As a variant, the main cavity 52 comprises a section, namely a width and / or a depth, which changes in stages or continuously.

According to one embodiment visible in Figures 13 and 14, the relief form 46 comprises several main cavities, a first main cavity 52 intended for the main connecting element 40, second and third main cavities 52 ', 52 ”, arranged on either side of the first main cavity 52, intended for the secondary connecting elements 41.

In addition to the (or) main cavity (s) 52, the relief form 46 comprises at least one branch 56. According to different configurations, the relief form 46 comprises several branches 56, each s' extending from a main cavity 52 towards at least one of the first and second longitudinal and lateral edges 48.1, 48.2, 50.1, 50.2. Each branch 56 comprises an end distant from the first and second longitudinal and lateral edges 48.1, 48.2, 50.1, 50.2.

According to one embodiment visible in Figures 5 and 6, the branches 56 are rectilinear. According to one embodiment visible in FIG. 7, at least one so-called main branch 56 comprises at least one branch and is divided into at least two secondary branches 58. At the level of the branch, the secondary branches 58 form an angle of approximately 60 ° between them.

The branches 56 have arrangements and / or geometries so that they are distributed approximately homogeneously near each main cavity 52. As illustrated in detail in Figures 8 to 10, each branch 56 comprises a bottom 60.1 as well as two side walls 60.2 delimiting, with the first panel 42 when it is connected to the second panel 44, a section S (hatched on figure 9).

Each branch 56 has a first end 56.1 connected to the main cavity 52 or closest to the latter as well as a second end 56.2 furthest from the main cavity 52.

According to one configuration, each branch 56 comprises a section which decreases between the first end 56.1 and the second end 56.2 (along the Z axis shown in Figure 8). According to an embodiment visible in Figure 8, a first branch 56 comprises a section which gradually decreases continuously from the first end 56.1 to the second end 56.2. Alternatively, a branch 56 ’comprises a section which decreases in stages. According to another variant, a branch 56 ’’ comprises a section which decreases in stages and gradually continuously.

According to one configuration, a branch 56 has a constant width (distance between the side walls 60.2) and a depth (distance between the bottom 60.1 and the first panel 42 when it is connected to the second panel 44) which gradually decreases by continuously and / or in stages from the first end 56.1 to the second end 56.2.

[0080] According to another configuration, a branch 56 ′ has a constant depth and a width which gradually decreases continuously and / or in stages from the first end 56.1 to the second end 56.2.

[0081] According to another configuration, a branch 56 "has a depth and a width which gradually decreases continuously and / or in stages from the first end 56.1 to the second end 56.2.

According to one embodiment, the stepwise reduction of the section of the branches 56 or of the main cavities 52 is obtained by means of one or more bending (double folding).

According to one configuration, the second panel 44 has a thickness of the order of 5 mm. The main cavity 52 has a width of the order of 200 mm and a depth varying from 30 mm to 100 mm, and in particular from 70 mm to 100 mm. The branches 56 are spaced from the longitudinal and lateral edges 48.1, 48.2, 50.1, 50.2 by a distance greater than or equal to approximately 150 mm. They have a width of between 30 mm and 50 mm. The side walls 54.2, 60.2 of the main cavity 52 or branches 56 are interconnected, with the bottom 54.1 or with the rest of the second panel 44 by rounded angles having a radius of curvature of the order of 27 mm.

Each main or secondary connecting element 40, 41 comprises at least one plate 62 having an edge 64 connected to the aerodynamic structure 34 mobile.

According to a first embodiment, the edge 64 is connected to the first panel 42. According to another embodiment, the edge 64 is connected to the second panel 44 outside the relief shape 46.

According to other embodiments visible in Figures 5, 11 to 16, the edge 64 is connected to the bottom 54.1 and / or to a side wall 54.2 of a main cavity 52 as well as to the second panel 44 in apart from the relief shape 46. These embodiments ensure better transmission of forces between the mobile aerodynamic structure 34 and the main or secondary connecting element 40, 41.

According to a configuration visible in Figure 12, the edge 64 has a profile allowing it to match the shape of the second panel 44 to the right of a main cavity 52. Thus, the edge 64 comprises a first section 64.1 in contact with the second panel 44 outside the relief shape 46, a second section 64.2 in contact with the side wall 54.2 of the main cavity 52 and a third section 64.3 in contact with the bottom 54.1 of the main cavity 52.

According to one embodiment, the plate 62 of each main or secondary connecting element 40, 41 is connected to the aerodynamic structure 34 movable by welding.

According to one embodiment shown in Figure 17, the second panel 44 consists only of the (or) shape (s) in relief 46. In other words, the second panel is limited to the (or) shape (s) in relief 46.

In Figure 17, the relief form 46 comprises a main cavity 52 and a plurality of main branches 56. Of course, the relief form 46 could include several main cavities 52 and a plurality of main branches 56, as well as 'a plurality of secondary branches 58.

The or each relief shape 46 is surrounded, in part, by at least one sole 66. More precisely, the main cavity (s) 52, each branch 56 and each secondary branch 58 is surrounded by at least one sole 66. The side walls 54.2 of the main cavity 52 are arranged obliquely with respect to the bottom 54.1 and with respect to the sole (s) 66. Likewise, the side walls 60.2 of the branches 56 are arranged obliquely with respect to the bottom 60.1 and with respect to the sole (s) 66. The side walls 54.2, 60.2 can be arranged perpendicular to the bottom 54.1, 60.1 and to the soles 66. The side walls 54.2, 60.2 respectively connect the bottom 54.1, 60.1 to the soles 66.

The sole (s) 66 constitute the second face 44.2 of the second panel 44. The sole (s) 66 are flat or slightly curved. The sole (s) 66 are shaped like the first panel 42. Thus, apart from the raised shape (s) 46, the sole (s) 66 of the second panel 44 are intimately pressed against the first panel 42.

According to one embodiment shown in Figures 17 and 18, the second panel 44 comprises at least one reinforcing rib 68 arranged on the bottom 60.1 of a branch 56 of the relief form 46. Of course, one, several, or each branch 56 may comprise such a reinforcing rib 68. Likewise, although not shown, the main cavity 52 may comprise at least one such reinforcing rib 68 arranged on its bottom 54.1. Likewise, although not shown, one, more, or each secondary branch 58 can comprise at least one such reinforcing rib 68 arranged on its bottom. The reinforcing rib 68 makes it possible to stiffen the branch 56 at the bottom of which it is arranged.

The reinforcing rib 68 is rectilinear and extends substantially parallel to the side walls 60.2 of the branches 56. The reinforcing rib 68 has a bottom wall 70 and side walls 72 which connect the bottom wall 70 to the bottom 60.1 . The bottom wall 70 is substantially parallel to the bottom 60.1. The side walls 72 are arranged obliquely with respect to the bottom 60.1 and with respect to the bottom wall 70. The reinforcing rib 68 is recessed at the level of the first face 44.1 of the second panel 44 and protrudes at the level of the second side 44.2.

According to one embodiment shown in Figures 19 and 20, the aerodynamic structure 34 comprises an intermediate panel 74. The intermediate panel 74 is made of a metallic material or of a composite material. The intermediate panel 74 is produced by draping, or by injection, or by cutting a metal plate or a composite material. The intermediate panel 74 is substantially flat. The thickness of the intermediate panel 74 is substantially constant.

As shown in Figure 20, the intermediate panel 74 is intended to be arranged between the first panel 42 and the second panel 44. The intermediate panel 74 has a first face 75.1 oriented towards the second face 42.2 of the first panel 42 and a second face 75.2 oriented towards the second face 44.2 of the second panel 44. The intermediate panel 74 constitutes an interface between the first and second panels 42, 44, in particular at the level of the main 40 or secondary 41 connecting elements.

The intermediate panel 74 comprises a first branch 76, for example rectilinear, which extends longitudinally to the first longitudinal edge 48.1 when the intermediate panel 74 is arranged between the first and second panels 42, 44. The first branch 76 has a shape substantially identical to the peripheral shape of part of the main cavity 52. The first branch 76 can also be curved. The first branch 76 is distant from the first longitudinal edge 48.1. A first end 77.1 of the first branch 76 is near the first side edge 50.1, and a second end 77.2 of the first branch 76 is near the second side edge 50.2. The first and second ends 77.1, 77.2 are spaced from the first and second side edges 50.1, 50.2.

The intermediate panel 74 also comprises a second branch 78, which has a shape substantially identical to the peripheral shape of a part of the main cavity 52. The second branch 78 has rectilinear portions and / or curved portions. The second branch 78 comprises first and second ends 80.1, 80.2 connected to the first branch 76. The width of the second branch 78 is less than or equal to the width of the first branch 76.

The intermediate panel 74 also comprises a plurality of third branches 82, each having a shape substantially identical to the shape of a branch 56. Each third branch 82 has a first end 84.1 connected to the second branch 78, as well as a second end 84.2 further away from the second branch 78. Each third branch 82 extends from the second branch 78 towards at least one of the first and second lateral and longitudinal edges 48.1, 48.2, 50.1, 50.2. The second end 84.2 of each third branch 82 is distant from the first and second lateral and longitudinal edges 48.1, 48.2, 50.1, 50.2. As shown in Figure 19, the third branches 82 include rectilinear portions. The third branches 82 can also include curved portions. The third branches 82 have lengths (distance between the first and second ends 84.1, 84.2) that are different from each other. The width of the third branches 82 is less than or equal to the width of the second branch 78. [0100] The intermediate panel 74 also comprises a plurality of fourth branches 83, each having a shape substantially identical to the shape of a secondary branch 58. Each fourth branch 83 has a first end 85.1 connected to the third branch 82, as well as 'a second end 85.2 more distant from the third branch 82. In particular, a third branch 82 has at least one branch and is divided into at least two fourth branches 83. Each fourth branch 83 extends from the third branch 82 towards at least one of the first and second lateral and longitudinal edges 48.1, 48.2, 50.1, 50.2. The second end 85.2 of each fourth branch 83 is distant from the first and second lateral and longitudinal edges 48.1, 48.2, 50.1, 50.2. As shown in FIG. 19, the fourth branches 83 comprise rectilinear portions. The fourth branches 83 can also include curved portions. The fourth branches 83 have different lengths from one another. The width of the fourth branches 83 is substantially equal to, or even less than, the width of the third branches 82.

[0101] The third and fourth branches 82, 83 have arrangements and / or geometries so that they are distributed approximately homogeneously around the second branch 78.

For each first, second, third and fourth branches 76, 78, 82, 83, the width of the branch is substantially constant over its length. Of course, the width of the branch 76, 78, 82, 83 could vary along said branch, and in particular be reduced from its first end 77.1, 80.1, 84.1, 85.1 towards its second end 77.2, 80.2, 84.2, 85.2.

[0103] According to one configuration, the intermediate panel 74 has a peripheral shape similar to the peripheral shape of the relief shape 46. From a top view of the second panel 44, the intermediate panel 74 is substantially superimposed on the shape. embossed 46.

According to this configuration, the intermediate panel 74 is inserted between the first and second panels 42, 44. In this configuration, the second faces 42.2, 44.2 of the first and second panels 42, 44 are pressed against each other apart from the shape (s) in relief 46, the intermediate panel 74 being inserted between the first and second panels 42, 44, at the level of the shape (s) in relief 46.

[0105] According to another configuration, the intermediate panel 74 has a peripheral shape similar to the peripheral shape of the relief shape 46, including the soles 66. From a top view of the second panel 44, the intermediate panel 74 is substantially superimposed on the relief form 46 and on the soles 66. According to this configuration, the intermediate panel 74 is inserted between the first and second panels 42, 44. In this configuration, the second face 42.2 of the first panel 42 is pressed against the first face 75.1 of the intermediate panel 74 and the second face 44.2 of the second panel 44 is pressed against the second face 75.2 of the intermediate panel 74 outside the ( or) relief shape (s) 46 (ie at the level of the soles 66).

[0106] Advantageously, an aerodynamic structure 34 comprising an intermediate panel 74 fits on different aircraft, or at different locations of the same aircraft. In particular, a first aerodynamic structure 34.1 comprises a first panel 42 having a first aerodynamic surface of a first type, a second panel 44, and an intermediate panel 74 having a first shape; and a second aerodynamic structure 34.2 comprises a first panel 42 having a first aerodynamic surface of a second type different from the first type, a second panel 44 identical to the second panel of the first aerodynamic structure 34.1, and an intermediate panel 74 having a second shape different from the first form. Thus, the second panel 44 is generic for different aerodynamic structures 34, and the first panel 42 and the intermediate panel 74 are specific, that is to say adapted according to the desired aerodynamic surface, and therefore to the location of the aerodynamic surface. the aerodynamic structure in the aircraft.

According to one embodiment shown in Figures 21 and 22, the aerodynamic structure 34 comprises at least one plate 90 in the general shape of S. The plate 90 is in excess of the second panel 44, on the second face 44.2. The plate 90 is made of composite material or of metal. Plate 90 is welded to second panel 44. Plate 90 has a substantially constant thickness. The plate 90 comprises a first section 92.1 extending along a part of the bottom 54.1 of the main cavity 52, a second section 92.2 extending along a part of a side wall 54.2 of the main cavity 52 , and a third section 92.3 extending along a part of a sole 66 surrounding the main cavity 52. The second section 92.2 connects together the first and third sections 92.1, 92.3. The first section 92.1 is substantially parallel to the bottom 54.1 of the main cavity 52. The third section 92.3 is substantially parallel to the sole 66 of the cavity main 52. The second section 92.2 is substantially parallel to the side wall

54.2 of the main cavity 52, and is arranged obliquely with respect to the first and third sections 92.1, 92.3.

The second panel 44 comprises a cavity 94 located on a sole 66 of the main cavity 52, along the longitudinal edge 48.1 of the aerodynamic structure 34. The cavity 94 is located at least opposite the location of the third section 92.3 of the plate 90 on the second panel 44, so that when the first and second panels 42, 44 are assembled to form the aerodynamic structure 34; the third section 92.3 fills at least part of said cavity 94. The plate 90 thus makes it possible to fill the cavity 94 which is defined in the second panel 44, and which remains between the first and second panels 42, 44 during assembly. of the aerodynamic structure 34. The plate 90 is disposed inside the aerodynamic structure 34.

[0109] The plate 90 is centered in the cavity 94. According to one configuration, for a mobile aerodynamic structure 34, the plate 90 and the cavity 94 are arranged at a location corresponding to the location of the main 40 or secondary 41 connecting elements. In other words, the plate 90 and the cavity 94 are arranged to the right of the implantation zone of the main 40 or secondary connecting elements 41. In FIG. 21, the plate 90 is arranged to the right of the implantation zone of the Main connecting elements 40. The plate 90 thus makes it possible to reinforce the connection internally, at the level of the main 40 or secondary 41 connecting elements.

[0110] According to one embodiment shown in Figure 22, the aerodynamic structure 34 comprises at least one filler 88. The filler element is in excess of the second panel 44, on the second face 44.2. The filling element 88 is made of a short-fiber thermoplastic composite material. According to one configuration, the filling element 88 is deposited on the second face

44.2 of the second panel 44, then the composite material constituting the filling element is polymerized. According to another configuration, the filling element 88 is produced beforehand, then is glued to the second face 44.2 of the second panel 44. A filling element 88 has a thickness between 1 and 5 mm, preferably between 3 and 4. , 5 mm. The thickness of the filler 88 varies along the length of the sole 66.

[0111] The filling element 88 is arranged in at least part of the cavity 94, in order to fill said cavity 94. In FIG. 22, a filling element 88 is arranged. on each side of the plate 90. The depth of the cavity 94 varies according to the variations in thickness of the filling element 88. The depth of the filling element 88 is maximum in line with the plate 90, and decreases. moving away from plate 90.

As shown in Figure 22, each filling element 88 is arranged between the second panel 44 and the first panel 42 (shown in dotted lines). A filling element 88 thus makes it possible to fill a cavity 94 which is defined in the second panel 44, and which remains between the first and second panels 42, 44 during the assembly of the aerodynamic structure 34.

The filling element (s) 88 and the plate 90 therefore make it possible to completely fill the cavity 94 of the second panel 44, which remains between the first and second panels 42, 44 during assembly of the aerodynamic structure 34. The filling element (s) 88 and the plate 90 allow continuity of the contact surfaces between the first and second panels 42, 44.

According to one configuration, for a mobile aerodynamic structure 34, each filling element 88 and the cavity 94 are arranged at a location corresponding to the location of the main 40 or secondary connecting elements 41. In other words, each filling element 88 and the cavity 94 are arranged to the right of the implantation zone of the main 40 or secondary connecting elements 41. In FIG. 22, each filling element 88 is arranged to the right of the implantation zone of the secondary connecting elements. 41. The filling elements 88 thus make it possible to reinforce the connection internally, at the level of the main 40 or secondary connecting elements 4L.

[0115] According to a configuration not shown, the plate 90 and the filling element 88 are in excess on the second face 44.2 of the second panel 44; and the first panel 42 has a cavity. This cavity of the first panel 42 is located opposite the location of the third section 92.3 of the plate 90 and of the filling element 88 on the second panel 44, so that when the first and second panels 42, 44 are assembled to form the aerodynamic structure 34, the third section 92.3 and the filling element 88 completely fill said cavity.

[0116] According to a configuration not shown, when the aerodynamic structure 34 comprises an intermediate panel 74, the filling element 88 and the plate 90 make it possible to completely fill the cavity 94 of the second panel 44, which is defined between the second panel 44 and the intermediate panel 74 during the assembly of the aerodynamic structure 34.

[0117] According to a configuration not shown, the plate 90 and the filling element 88 are in excess on the second face 44.2 of the second panel 44; and the intermediate panel 74 has a cavity. This cavity of the intermediate panel 74 is located opposite the location of the third section 92.3 of the plate 90 and of the filling element 88 on the second panel 44, so that when the aerodynamic structure 34 is assembled , the third section 92.3 and the filling element 88 completely fill said cavity.

[0118] According to one embodiment shown in FIG. 23, the plate 90 is in excess of the second panel 44, on the first face 44.1. The plate 90 of FIG. 23 is identical to the plate 90 of FIG. 21, but is arranged outside the aerodynamic structure 34. The plate 90 thus makes it possible to strengthen the connection externally, at the level of the main connecting elements 40. or secondary 4L

According to one embodiment shown in FIG. 24, the aerodynamic structure 34 comprises at least one plate 96 in the general shape of a T. The plate 96 is in excess of the second panel 44, on the second face 44.2. The plate 96 is made of a composite material or of metal. According to one configuration, the plate 96 is welded to the second panel 44. According to another configuration, when the plate 96 is metallic, the plate 96 is conformed to the second panel 44, directly on the second panel 44. According to one configuration, the plate 96 has a constant thickness. According to another configuration, the thickness of the plate 96 varies. The plate 96 comprises a first section 98.1 extending along a part of the bottom 54.1 of the main cavity 52, a second section (not visible in the figures) extending along a part of a side wall 54.2 of the main cavity 52, a third section 98.3 extending along a part of a sole 66 surrounding the main cavity 52, a fourth section 98.4 extending along a part of a sole 66 surrounding the main cavity 52 from the third section 98.3 and towards the side edge 50.1 and a fifth section 98.5 extends along a part of a sole 66 surrounding the main cavity 52 from the third section 98.3 and in the direction from the side edge 50.2. The second section connects together the first and third sections 98.1, 98.3. The first section 98.1 is substantially parallel to the bottom 54.1 of the main cavity 52. The third section 98.3 is substantially parallel to the sole 66 of the main cavity 52. The second section is substantially parallel to the side wall 54.2 of the main cavity 52, and is arranged obliquely with respect to the first and third sections 98.1, 98.3. The third section 98.3 connects together the fourth and fifth sections 98.4, 98.5. The fourth and fifth sections 98.4, 98.5 are substantially parallel to the sole 66 of the main cavity 52.

[0120] The cavity 94 of the second panel 44 is located opposite the location of the third, fourth and fifth sections 98.3, 98.4, 98.5 of the plate 96 on the second panel 44, so that when the first and second panels 42 , 44 are assembled to form the aerodynamic structure 34; the third, fourth and fifth sections 98.3, 98.4, 98.5 fill said cavity 94. The plate 96 thus makes it possible to completely fill the cavity 94 which is defined in the second panel 44, and which remains between the first and second panels 42, 44 during of the assembly of the aerodynamic structure 34. The plate 96 is disposed inside the aerodynamic structure 34. The plate 96 thus allows continuity of the contact surfaces between the first and second panels 42, 44.

[0121] The plate 96 and the cavity 94 are arranged at a location corresponding to the location of the main 40 or secondary connecting elements 4L In other words, the plate 96 and the cavity 94 are arranged to the right of the implantation zone of the main 40 or 4L secondary connecting elements The plate 96 thus makes it possible to reinforce the connection internally, at the level of the main 40 or secondary 4L connecting elements.

[0122] According to a configuration not shown, the plate 96 is extra thick on the second face 44.2 of the second panel 44, and the first panel 42 has a cavity. This cavity of the first panel 42 is located opposite the location of the third, fourth and fifth sections 98.3, 98.4, 98.5 of the plate 96 on the second panel 44, so that when the first and second panels 42, 44 are assembled to form the aerodynamic structure 34, the third, fourth and fifth sections 98.3, 98.4, 98.5 completely fill said cavity.

[0123] According to a configuration not shown, when the aerodynamic structure 34 comprises an intermediate panel 74, the plate 96 makes it possible to completely fill the cavity 94 of the second panel 44, which is defined between the second panel 44 and the intermediate panel 74 during assembly of the aerodynamic structure 34.

[0124] According to a configuration not shown, the plate 96 is increased in thickness on the second face 44.2 of the second panel 44, and the intermediate panel 74 comprises a cavity. This cavity of the intermediate panel 74 is located opposite the location of the third, fourth and fifth sections 98.3, 98.4, 98.5 of the plate 96 on the second panel 44, so that when the aerodynamic structure 34 is assembled , the third, fourth and fifth sections 98.3, 98.4, 98.5 of the plate 96 completely fill said cavity.

[0125] According to one embodiment shown in FIG. 25, the first panel 42 comprises an extra thickness 100, on its second face 42.2, near its trailing edge 102. The extra thickness 100 is formed integrally with the first panel 42. The extra thickness 100 varies along the first panel 42. In particular, the extra thickness 100 comprises a first portion 104.1 the thickness of which increases from the trailing edge 102 towards the rest of the first panel 42, followed by a second portion 104.2 whose thickness is constant, and a third portion 104.3 whose thickness decreases from the second portion 104.2 towards the rest of the first panel 42.

The ends of the sole (s) 66 of the second panel 44 are curved, so as to be pressed against the extra thickness 100 of the first panel 42. The ends of the sole (s) 66 are curved in the direction of the first face 44.1, that is to say in the direction of the relief shapes 46 and in the direction opposite to the extra thickness 100. Thus, the shape of the soles 66 is adapted, more precisely conformed, to the extra thickness 100 of the first panel 42, so that the first and second panels 42, 44 are intimately pressed against one another.

[0127] The extra thickness 100 of the first panel 42 makes it possible to transfer the forces undergone by the second panel 44 to said first panel 42, at the level of the trailing edge 102. The curvature of the sole (s) 66 to the end of the second panel 44 makes it possible to integrate an aerodynamic function in the second panel 44, at the level of the trailing edge 102 of the first panel 42. In fact, the extra thickness 100 of the first panel 42 and the curvature of the sole (s) (s) 66 of the second panel 44 ensure aerodynamic continuity at the trailing edge 102 of the first panel 42.

[0128] According to one embodiment, a method of manufacturing an aerodynamic structure of an aircraft comprises a step of shaping the second panel 44 by stamping so as to obtain the relief shape 46. Beforehand, the method can comprise a step of conformation of the first and second panels 42 and 44 in the same manner according to a desired aerodynamic profile. After shaping the second panel 44 by stamping, the method comprises a step of joining by welding the first and second panels 42, 44, by pressing their second face 42.2, 44.2 against each other outside the (or) relief shape (s) 46.

[0130] According to one embodiment, the method comprises a step of inserting the intermediate panel 74 between the first and second panels 42, 44, before the junction of the first and second panels 42, 44 together.

According to one embodiment, during the joining step, the second face 44.2 of the second panel 44 and the second face 45.2 of the intermediate panel 74 are pressed against each other outside the (or ) shape (s) in relief 46, and the second face 42.2 of the first panel 42 and the first face 75.1 of the intermediate panel 74 are pressed against each other. The first and second panels 42, 44 are joined together by welding, via the intermediate panel 74.

Finally, for a mobile aerodynamic structure 34, the method comprises a step of fixing by welding at least one connecting element 40, 41 on the second panel 44, at the level of the relief shape 46, after the step of shaping the second panel 44, before or after the step of joining the first and second panels 42, 44 together.

[0133] The method of the invention makes it possible to obtain an aerodynamic structure from a small number of parts, which tends to reduce manufacturing time and costs.

[0134] The fact of creating ribs on the second panel 44 by stamping makes it possible, with equal mechanical characteristics, to reduce the mass of the aerodynamic structure 34 compared to the prior art.

Claims

1. A method of manufacturing an aerodynamic structure (34) comprising a first panel (42) having first and second faces (42.1, 42.2), the first face (42.1) forming an aerodynamic face (F34), as well as a second reinforced panel (44) having first and second faces (44.1, 44.2), the second face (44.2) of the second panel (44) being oriented towards the second face (42.1) of the first panel (42), characterized in that the manufacturing method comprises a step of shaping the second panel (44), during which the second panel (44) is stamped to obtain at least one relief shape (46), recessed at the level of the second face (44.2 ), as well as a step of joining the first and second panels (42, 44) by pressing their second face (42.2, 44.2) against each other outside of the shape (s) in relief (46).

2. The manufacturing method according to claim 1, characterized in that, before the joining step, the method comprises a step of inserting an intermediate panel (74) between the first and second panels (42, 44), the intermediate panel (74) comprising first and second faces (45.1, 45.2), the first face (45.1) being oriented towards the second face

(42.2) of the first panel (42) and the second face (45.2) being oriented towards the second face

(44.2) of the second panel (44).

3. Manufacturing process according to claim 2, characterized in that, during the joining step, the second face (44.2) of the second panel (44) and the second face (45.2) of the intermediate panel (74) are plated. against each other outside the relief shape (s) (46), and the second face (42.2) of the first panel (42) and the first face (75.1) of the intermediate panel (74 ) are pressed against each other.

4. Manufacturing process according to one of the preceding claims, characterized in that during the joining step, the first and second panels (42, 44) are connected by welding.

5. Manufacturing process according to one of the preceding claims, characterized in that after the step of shaping the second panel (44), the manufacturing process comprises a step of fixing at least one connecting element (40). , 41) on the second panel (44) at the level of the relief shape (46).

6. Aerodynamic structure (34) comprising a first panel (42) having first and second faces (42.1, 42.2), the first face (42.1) forming an aerodynamic face (F34), as well as a second reinforced panel (44) having first and second faces (44.1, 44.2), the second face (44.2) of the second panel (44) being oriented towards the second face (42.1) of the first panel (42), the second panel (44) comprising at least one relief shape (46), recessed at the level of the second face (44.2), the second faces (42.2, 44.2) of the first and second panels (42, 44) being connected between they apart from the form (s) in relief (46), characterized in that the aerodynamic structure (34) comprises an intermediate panel (74) arranged between the first and second panels (42, 44).

7. Aerodynamic structure (34) according to the preceding claim, characterized in that the aerodynamic structure comprises first and second longitudinal edges (48.1, 48.2), first and second lateral edges (50.1, 50.2) as well as at least one element main or secondary link (40, 41) positioned near the first longitudinal edge (48.1) and in that the relief shape (46) comprises at least one main cavity (52) to which is connected at least one of the elements of main or secondary link (40, 41).

8. Aerodynamic structure (34) according to claim 7, characterized in that the relief shape (46) comprises at least one branch (56) which extends in the direction of at least one of the first and second longitudinal and lateral edges. (48.1, 48.2, 50.1, 50.2), from a first end (56.1) connected to the main cavity (52) to a second end (56.2), the second end (56.2) of each branch (56) being distant first and second longitudinal and lateral edges (48.1, 48.2, 50.1, 50.2).

9. Aerodynamic structure (34) according to claim 8, characterized in that the intermediate panel (74) comprises at least one branch (76, 78, 82) of substantially identical shape to a shape of the branch (56) of the form in relief (46) or in a peripheral shape of a part of the cavity (52).

10. Aerodynamic structure (34) according to one of claims 8 or 9, characterized in that the main cavity (52) or at least one branch (56) of the relief form (46) comprises a reinforcing rib (58 ).

11. Aerodynamic structure (34) according to one of claims 7 to 10, characterized in that the aerodynamic structure (34) comprises at least one plate (90, 96) arranged between the main or secondary connecting element (40, 41) and the first panel (42).

12. Aerodynamic structure (34) according to one of claims 6 to 11, characterized in that the second face (42.2) of the first panel (42) has an extra thickness (100), and in that the second face (44.2) of the second panel (44) is conformed to said extra thickness (100).

13. Aerodynamic structure (34) according to one of claims 7 to 11 or according to claim 12 in combination with claim 7, characterized in that each connecting element (40, 41) comprises at least one plate (62) having a song (64) which matches the shape of the second panel (44) in line with a main cavity (52).

14. Aerodynamic structure (34) according to the preceding claim, characterized in that the edge (64) is connected to the second panel (44) outside the relief shape (46) and to a bottom (54.1) and a side wall (54.2) of the main cavity (52).

15. Aircraft comprising at least one aerodynamic structure (34) according to one of claims 6 to 14.