WO1999004952A1 - Procede de fabrication de pieces en materiau composite a matrice thermoplastique - Google Patents

Procede de fabrication de pieces en materiau composite a matrice thermoplastique Download PDF

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Publication number
WO1999004952A1
WO1999004952A1 PCT/FR1998/001584 FR9801584W WO9904952A1 WO 1999004952 A1 WO1999004952 A1 WO 1999004952A1 FR 9801584 W FR9801584 W FR 9801584W WO 9904952 A1 WO9904952 A1 WO 9904952A1
Authority
WO
WIPO (PCT)
Prior art keywords
reinforcing elements
skin
blanks
strip
manufacture
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/FR1998/001584
Other languages
English (en)
French (fr)
Inventor
Serge Maison
Serge Meunier
Cédric THIBOUT
Luc Mouton
Hervé PAYEN
Philippe Vautey
Carole Coiffier-Colas
Joël DELBEZ
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Dassault Aviation SA
Airbus Group SAS
Airbus Helicopters SAS
Original Assignee
Dassault Aviation SA
Airbus Group SAS
Eurocopter France SA
Eurocopter SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dassault Aviation SA, Airbus Group SAS, Eurocopter France SA, Eurocopter SA filed Critical Dassault Aviation SA
Priority to EP98939716A priority Critical patent/EP0998383B1/fr
Priority to CA002297266A priority patent/CA2297266C/fr
Priority to US09/462,748 priority patent/US6613258B1/en
Priority to JP2000503980A priority patent/JP2001510746A/ja
Priority to DE69809427T priority patent/DE69809427T2/de
Publication of WO1999004952A1 publication Critical patent/WO1999004952A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
    • B64C1/06—Frames; Stringers; Longerons ; Fuselage sections
    • B64C1/12—Construction or attachment of skin panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7858—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined
    • B29C65/7879—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined said parts to be joined moving in a closed path, e.g. a rectangular path
    • B29C65/7882—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined said parts to be joined moving in a closed path, e.g. a rectangular path said parts to be joined moving in a circular path
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/524—Joining profiled elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/61—Joining from or joining on the inside
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72141—Fibres of continuous length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/32—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
    • B64C1/06—Frames; Stringers; Longerons ; Fuselage sections
    • B64C1/061—Frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
    • B64C1/06—Frames; Stringers; Longerons ; Fuselage sections
    • B64C1/064—Stringers; Longerons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
    • B64C1/06—Frames; Stringers; Longerons ; Fuselage sections
    • B64C1/068—Fuselage sections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
    • B64C2001/0054—Fuselage structures substantially made from particular materials
    • B64C2001/0072—Fuselage structures substantially made from particular materials from composite 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/40—Weight reduction
    • 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
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1089—Methods of surface bonding and/or assembly therefor of discrete laminae to single face of additional lamina

Definitions

  • the invention relates to a method for manufacturing large parts, including a skin and reinforcing elements, from a composite material with a thermoplastic matrix.
  • the process according to the invention can be used in numerous industrial sectors, since it is desired to be able to benefit from the advantages specific to composite materials for the manufacture of large parts comprising a skin and added reinforcing elements.
  • the method according to the invention can in particular be used to manufacture sections of aircraft fuselage, shell rings of aircraft reactor nacelles, etc.
  • thermosetting resin the vast majority of parts made of composite materials currently used in the aeronautical industry are parts made from a thermosetting resin. In fact, this type of resin was initially the only one which provided the desired mechanical properties.
  • thermosetting matrix The production of parts made of composite materials with a thermosetting matrix, however, has a significant drawback. Indeed, due to the thermosetting nature of the resin used, the manufacture of each part necessarily ends with a relatively long polymerization operation, generally carried out in an autoclave.
  • thermoplastic resins such as PEEK resin (Polyetheretherketone)
  • PEEK resin Polyetheretherketone
  • thermoplastic materials with a thermoplastic matrix have, in addition to the advantages of the composite materials with an organic matrix mentioned above, good resistance to impact and to fire as well as a low moisture uptake. Finally, the semi-finished products are stored at room temperature and have a practically unlimited lifetime, because the resin which permeates the wires is already polymerized.
  • these consolidation operations mainly have the function of creating the connection between the different layers constituting, on the one hand, the skin and, on the other hand, each of the reinforcing elements, while eliminating the porosities. They consist of the application of pressure on the element to be consolidated, and its heating to a determined temperature, higher than the melting temperature of the resin. These consolidation operations are carried out in an autoclave. This makes this process ill-suited to the manufacture of parts having a large skin size, for reasons identical to those which have been mentioned in the context of the production of parts made of composite material with thermosetting matrix.
  • the subject of the invention is precisely a method for manufacturing large parts, such as aircraft fuselage sections, from a composite material with a thermoplastic matrix, in a particularly rapid and inexpensive manner, suitable for manufacturing. industrial at a relatively high rate, without any real size limitation because neither the skin nor the final structure obtained must be autoclaved at the end of their manufacture.
  • this result is obtained by means of a process for manufacturing large parts, in composite material, including a skin and reinforcing elements, characterized in that it comprises the following stages:
  • the time for manufacturing the parts is particularly short since the assembly of the skin and the reinforcing elements and the manufacture of the skin are simultaneous.
  • the reinforcing elements of a given part can be manufactured when the skin of the previous part is itself in the course of manufacture.
  • the reinforcing elements are produced by automated continuous deposition of a strip of long fibers impregnated with polymerized thermoplastic resin, so as to form a panel, comparable to a sheet in a metal part. classic, by cutting blanks in this panel, then by consolidating and shaping these blanks. Generally the blanks are consolidated before being shaped.
  • the blanks can be consolidated either in an autoclave or in a heating press. It should be noted that consolidation in an autoclave or in a heating press then relates to parts of relatively small dimensions, so that an ordinary autoclave or heating press, of conventional dimensions can be used and that several blanks can be consolidated there simultaneously.
  • the blanks are preferably formed by thermoforming. If the correct orientation of the fibers in the reinforcing element requires it, thermoforming may be preceded by a bending operation.
  • the blanks can be consolidated and shaped simultaneously by thermoforming in a heating press.
  • the method according to the invention is advantageously applied to the manufacture of a hollow part.
  • the reinforcing elements are then placed in recesses provided on a mandrel belonging to the tool, then the strip is continuously draped and consolidated on this mandrel by rotating it around its axis.
  • elements of reinforcement comprising beams, frames and local reinforcements.
  • FIG. 1 schematically illustrates a first step in the process according to the invention, in which beams, local reinforcements and frames are produced separately;
  • FIG. 2 is a cross-sectional view which schematically represents the final step of the method according to the invention, during which the skin is made simultaneously and its assembly with the reinforcing elements;
  • FIG. 3 is a perspective view illustrating the relative arrangement of beams and frames in the fuselage section that one wishes to manufacture.
  • such a fuselage section comprises an outer skin 10, as well as reinforcing elements constituted by healds 12, frames 14 and local reinforcements 16.
  • the rails 12 and the frames 14, oriented respectively in longitudinal and circumferential directions, constitute the framework of the fuselage (FIG. 3), in the same manner as when it is metallic.
  • the local reinforcements 16 form extra thicknesses which are added locally to the skin 10 in order to reinforce it, in particular in the regions where the portholes 17 are located (FIG. 3).
  • the method according to the invention can be used to manufacture any large-sized parts from a composite material with a thermoplastic matrix, formed by the assembly of a skin and reinforcing elements. Consequently, the shape and dimensions of the part may be different, as may the nature, number and arrangement of the reinforcing elements.
  • the invention is particularly suitable for the manufacture of a hollow part of revolution, it can also be applied to the manufacture of parts of different shapes, not of revolution.
  • the reinforcing elements formed here by the heddles 12, the frames 14 and the local reinforcements 16, are produced separately by draping, consolidation and shaping, from a strip 18 of long fibers impregnated with polymerized thermoplastic resin.
  • polymerized thermoplastic resin polymerized thermoplastic resin.
  • carbon fibers impregnated with PEEK resin polyetheretherketone
  • Fibers and / or a thermoplastic resin of different natures can however be used in certain applications, without departing from the scope of the invention.
  • a strip 18 is generally used, formed from unidirectional fibers linked together by the polymerized thermoplastic resin.
  • a strip of woven fibers, also impregnated with polymerized resin can however be used in certain cases.
  • the sheet 18 of fibers impregnated with polymerized thermoplastic resin is a flexible and non-adhesive strip, usually stored on a roll.
  • the step of draping the strip 18, illustrated schematically in a. in FIG. 1, consists in depositing the strip 18 over several thicknesses, to form a certain number of layers or folds, according to orientations which may or may not vary from one fold to another, to take account of the mechanical characteristics that we wish to obtain.
  • the number of folds superposed during this layup step also depends on the mechanical characteristics desired for the reinforcing elements 12, 14 and 16.
  • the lay-up step illustrated in a in FIG. 1 can be common to all the reinforcement elements constituted by the healds 12, the frames 14 and the local reinforcements 16, or on the contrary specific to each of these reinforcement elements, depending on whether these elements must have the same thickness or not.
  • the strip 18 can also be the same for all the reinforcing elements, or differ for some of them.
  • one or more types of flat panels 20 are thus produced by draping.
  • the draping operation of the strip 18, from the roller (not shown) on which the material is wound, is preferably provided by a draping head (not shown) suitable for draping a strip formed of long fibers impregnated of polymerized thermoplastic resin.
  • a draping head (not shown) suitable for draping a strip formed of long fibers impregnated of polymerized thermoplastic resin.
  • the lay-up head heats the strip 18 to a temperature above the melting temperature of the resin, then applying pressure to the deposited strip, in order to ensure its diffusion welding on the previously deposited strip.
  • the lay-up head then cools the strip immediately after its application, in order to prevent it from becoming detached again.
  • the strip 18 is deposited by the lay-up head on a flat, generally fixed support.
  • the panel or panels 20 obtained by this draping operation are therefore flat panels, preferably of large dimensions, which can be manufactured continuously within the framework of an industrial process.
  • Blanks 22 are cut from the panel or panels 20, either as these panels are produced, or subsequently. The cuts are made in order to obtain blanks whose dimensions are adapted to those of the reinforcing elements 12, 14 and 16 which it is desired to manufacture. These dimensions can also be slightly larger if necessary to perform a trimming after the shaping of the reinforcing elements.
  • the blanks 22 cut out from the panel or panels 20 then generally undergo a consolidation operation which mainly has the function of eliminating the porosities inside the material and of improve the connection between the different layers that constitute it.
  • This consolidation operation is characterized by the application of pressure on the blanks 22 (generally between 2 to 20 bars, depending on the type of material used), and by their heating to a temperature generally higher than the melting temperature of the resin, in order to ensure its softening (for example, at around 400 ° C. in the case of a PEEK resin).
  • the consolidation of the blanks 22 can be carried out in an autoclave or in a heating press.
  • the autoclaves used are conventional autoclaves, of conventional dimensions, since the dimensions of the blanks 22 to be consolidated correspond to the dimensions of the reinforcing elements of the part to be manufactured, before these elements are shaped.
  • several blanks 22 can be consolidated in the same autoclave, which provides significant time savings and savings.
  • the consolidation of the blanks 22 can also be done in a heating press such as that described in document EP-A-0 584 017.
  • the different consolidated blanks 22 are then shaped separately, as shown diagrammatically in c, d and e respectively for the heddles 12, the frames 14 and the local reinforcements 16.
  • the rails 12 are straight or substantially straight profiles, which have approximately in section an omega shape. Straight profiles of substantially different sections, for example in L, Z or U, can be manufactured in the same way, in order to be integrated into the final part.
  • the shaping of the reinforcing elements such as the heddles 12 is done by thermoforming, for example in a machine of the heating press type equipped with a punch and a die, or a punch and a bladder.
  • thermoforming for example in a machine of the heating press type equipped with a punch and a die, or a punch and a bladder.
  • the techniques for shaping by thermoforming parts made of a composite material with a thermoplastic matrix are well known, so that no detailed description will be made of them.
  • the reinforcing elements such as the local reinforcements 16, constituted by sections of panels slightly curved relative to a plane, can also be produced by thermoforming, in particular between a punch and a bladder, from planar blanks 22 previously consolidated.
  • the shaping can in particular be done in a heating press similar to that which is described in document EP-A-0 584 017, already cited.
  • the steps of consolidation and shaping of these reinforcing elements can also be simultaneous.
  • the flat blanks 22 cut from the panel 20 are then placed directly in a heating press which simultaneously performs these two functions.
  • a heating press similar to that described in EP-A-0 584 017 can be used.
  • the reinforcing elements such as the frames 14 are circular profiles or in an arc.
  • these sections have a U-shaped section. Any other section, for example L-shaped, can however be envisaged, without departing from the scope of the invention.
  • this blank In order to allow a circular element to be obtained from a plane blank 22 initially in the form of a straight strip, this blank must first of all be bent in its plane, to ensure the continuity of the fibers over the entire circumference of the item.
  • This bending can in particular be carried out using a device comparable to that which is described in document FR-A-2 635 484, after adaptation of this device to take account of the thermoplastic nature of the resin used.
  • This adaptation is reflected in particular by the addition of heating means, upstream of the conical rollers ensuring the bending of the strip.
  • this blank is formed by thermoforming, either between a punch and a die or between a punch and a bladder, in the same way as the heddles 12, the setting of which in shape has been described previously.
  • the tool 23 comprises a hollow mandrel 24, for example metallic, the outer surface of which has a shape complementary to that of the lower surface of the skin 10 of the fuselage section that it is desired to manufacture.
  • a mandrel 24 of circular shape has been shown in FIG. 2.
  • the hollow mandrel 24 is mounted on spokes 26, making it possible to connect it to a central hub 28, by which the mandrel can be rotated in the direction of the arrow F on the Figure 2.
  • This rotary drive can be provided by any suitable means allowing rotation of the mandrel 24 at a controlled constant speed, relatively slow.
  • the mandrel 24 On its outer surface, the mandrel 24 has recesses 30 whose shapes are complementary to those of the various reinforcing elements 12, 14 and 16. Thus, when the heddles 12, the frames 14 and the local reinforcements 16 are placed in these recesses 30, all of these reinforcing elements are flush with the external surface of the mandrel 24 between the recesses 30. As schematically illustrated in FIG. 3, the mounting of the heddles 12 and the crisscross frames 14 is made possible by the fact that notches 14a are formed, for example in the frames 14, at the places where these reinforcing elements cross. The notches 14a are formed before the healds 12 and the frames 14 are placed in the recesses 30.
  • the mandrel 24 is itself removable. To this end, it can be formed of several removable sectors assembled together, or able to be retracted on itself, or even in any other way allowing easy disassembly of the part when it is finished.
  • some of the reinforcing elements (in this case, the heddles 12) have recessed parts facing outwards, when these elements are placed in the recesses 30.
  • one place in these hollow parts of the cores 40 which prevent any deformation of the skin 10, when the latter is manufactured.
  • cores 40 are used in a material capable of being easily destroyed or dismantled when the part is finished (for example soluble cores).
  • the step following of the process can be started as illustrated in FIG. 2.
  • the skin 10 and the assembly of this skin and the reinforcing elements 12, 14 and 16 are carried out simultaneously, by draping and continuous consolidation of a strip 32 of long fibers impregnated with polymerized thermoplastic resin, directly on the mandrel 24 carrying these reinforcing elements.
  • the strip 32 of long fibers impregnated with resin is generally of the same nature as that which was used to manufacture the heddles 12, the frames 14 and local reinforcements 16. Thus, it is generally a strip of carbon fibers impregnated with PEEK resin (polyetheretherketone) already polymerized.
  • PEEK resin polyetheretherketone
  • the composite material forming the skin 10 may be different from that in which the reinforcing elements are made.
  • layup and continuous consolidation are carried out from a strip 32 initially wound on a reel 34.
  • the layup and continuous consolidation are provided by a lay-up head illustrated diagrammatically at 36.
  • This lay-up head 36 is mounted on a support (not shown) so as to move progressively parallel to the axis of the mandrel 24.
  • the strip 32 is wound in a helix around the mandrel, according to a layup sequence defined so as to gradually form the skin 10 of the part.
  • the strip 32 can also be deposited parallel to the axis of the mandrel 24.
  • lay-up head 36 is designed to simultaneously lay down the strip 32 on the mandrel 24, continuously consolidate the skin 10 thus produced, and assemble this skin 10 and the reinforcing elements constituted by the healds 12 , the frames 14 and the local reinforcements 16.
  • the lay-up head 36 subjects the material to a predetermined pressure and temperature cycle. This cycle includes heating the strip 32 immediately before its application to the mandrel 24, applying pressure to the strip 32 when it is applied to the mandrel, then cooling the strip which has just been deposited.
  • the preheating of the strip 32 is carried out at a temperature higher than the melting temperature of the resin, in order to make it sufficiently fluid to allow diffusion welding between the different layers deposited and to facilitate the elimination of the porosities.
  • a temperature in the region of 400 ° C. can be adopted in the case of a PEEK resin.
  • the strip 32 is applied against the mandrel 24, for example by a roller 38, at a pressure generally between 2 and 20 bars, depending on the type of material used.
  • the subsequent cooling of the deposited strip is intended to prevent the strip from becoming detached again. It aims to bring it down to a temperature below the melting temperature of the resin and, if possible, below its glass transition temperature.
  • the rotation of the mandrel 24 is stopped and the strip 32 is cut.
  • the skin 10 is then already consolidated and welded by diffusion to the reinforcing elements constituted in this case by the heddles 12, the frames 14 and the local reinforcements 16. Consequently, the fuselage section is obtained immediately, after dismantling or retraction of the mandrel 24 and removal of the cores 40 placed inside the heddles 12. In particular, the fuselage section thus obtained does not require subsequent passage in an autoclave.
  • the frame (not shown) which supports the mandrel 24 and the lay-up head 36 can also be used, if necessary, to integrate into the skin of the structure obtained protection against lightning and to ensure at least part of the finishing operations such as the deposition of a primary coating intended to receive a paint.
  • the method according to the invention makes it possible to manufacture, industrially and at low cost, parts made of composite material with large thermoplastic matrix, formed by the assembly of a skin and elements of reinforcement, practically without limitation of size.
  • a large number of usually metallic parts can thus be made of composite material, which makes it possible to benefit from the advantages specific to these materials.
  • the method according to the invention does not prohibit the subsequent addition of certain reinforcing elements or others made of different materials and in particular metallic, when the manufacture of these elements is not possible or too costly by techniques. for the production of composite materials with a thermoplastic matrix.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
PCT/FR1998/001584 1997-07-22 1998-07-20 Procede de fabrication de pieces en materiau composite a matrice thermoplastique Ceased WO1999004952A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
EP98939716A EP0998383B1 (fr) 1997-07-22 1998-07-20 Procede de fabrication de pieces en materiau composite a matrice thermoplastique
CA002297266A CA2297266C (fr) 1997-07-22 1998-07-20 Procede de fabrication de pieces en materiau composite a matrice thermoplastique
US09/462,748 US6613258B1 (en) 1997-07-22 1998-07-20 Method for making parts in composite material with thermoplastic matrix
JP2000503980A JP2001510746A (ja) 1997-07-22 1998-07-20 熱可塑性マトリックスを有する複合材料から成る航空機胴体部等の大寸法のパーツの組立方法
DE69809427T DE69809427T2 (de) 1997-07-22 1998-07-20 Verfahren zur herstellung von verbundgegenständen mit thermoplastischer matrix

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR97/09265 1997-07-22
FR9709265A FR2766407B1 (fr) 1997-07-22 1997-07-22 Procede de fabrication de pieces de grandes dimensions en materiau composite a matrice thermoplastique, telles que des troncons de fuselage d'aeronefs

Publications (1)

Publication Number Publication Date
WO1999004952A1 true WO1999004952A1 (fr) 1999-02-04

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PCT/FR1998/001584 Ceased WO1999004952A1 (fr) 1997-07-22 1998-07-20 Procede de fabrication de pieces en materiau composite a matrice thermoplastique

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US (1) US6613258B1 (https=)
EP (1) EP0998383B1 (https=)
JP (1) JP2001510746A (https=)
CN (1) CN1077842C (https=)
CA (1) CA2297266C (https=)
DE (1) DE69809427T2 (https=)
ES (1) ES2186202T3 (https=)
FR (1) FR2766407B1 (https=)
WO (1) WO1999004952A1 (https=)

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CA2297266A1 (fr) 1999-02-04
ES2186202T3 (es) 2003-05-01
FR2766407A1 (fr) 1999-01-29
JP2001510746A (ja) 2001-08-07
CN1270551A (zh) 2000-10-18
CA2297266C (fr) 2008-04-29
US6613258B1 (en) 2003-09-02
EP0998383A1 (fr) 2000-05-10
EP0998383B1 (fr) 2002-11-13
DE69809427D1 (de) 2002-12-19
FR2766407B1 (fr) 1999-10-15
DE69809427T2 (de) 2003-09-25
CN1077842C (zh) 2002-01-16

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