Method and apparatus for manufacturing structural elements of composite material having a z-shaped profile

Abstract

A method for manufacturing a structural element (2) of a composite material is described, the structural element extending in a straight or curved longitudinal direction (D), having a Z-shaped cross section and comprising a central web (2a) and two flanges (2b, 2c) in its final configuration, the two flanges extending from opposite ends of the web (2a) in their respective opposite directions at a given final angle; the method comprises the steps of: arranging a plurality of layers (3) of the composite material on a forming portion (4) of a molding die; laminating the layers (3) onto the forming portion (4) such that the web (2a) is at least partially arranged in its final configuration, such that a first flange (2b) is positioned relative to the web in the final configuration of the web. (2a) is arranged at a final angle to form the final configuration of the first flange, and the second flange (2c) is arranged at an initial angle different from and greater than the final angle relative to the portion of the web (2a) arranged as the final configuration of the web, to form the initial configuration of the second flange; the movable part (6) of the molding die is moved from a rest position to a bent position, the movable part being movable relative to the fixed part (5) of the molding die; the second flange (2c) is shifted from the initial configuration to the final configuration, in which the second flange is at the final angle relative to the portion of the web (2a) arranged as the final configuration of the web; the shifting step (d) is performed by the shifting step (c).

Description

[0001] Cross-reference to related applications

[0002] This patent application claims priority to Italian Patent Application No. 102020000028046, filed on November 23, 2020, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This invention relates to a method for manufacturing structural elements of composite materials, the structural elements extending in a straight or curved longitudinal direction and having a Z-shaped cross section relative to the longitudinal direction, particularly for structural elements of composite materials used in the aerospace field and forming part of the structure of an aircraft, such as beams, stringers, spars, etc. of an aircraft fuselage, and the following description will explicitly refer to these structural elements without loss of generality.

[0004] The present invention also relates to an apparatus for manufacturing structural elements of composite materials, the structural elements extending in a straight or curved longitudinal direction and having a Z-shaped cross section relative to the longitudinal direction, the structural elements being particularly used in the aerospace field for structural elements of composite materials that form part of the structure of an aircraft, such as beams, stringers, wing spars, etc. of the fuselage of an aircraft, and the following description will explicitly refer to these structural elements without loss of generality. Background Technology

[0005] It is known that structural components used in the aerospace field (e.g., fuselages and fuselage parts) are made of composite materials. This material is used to reduce the overall weight of the aircraft and to eliminate or minimize corrosion problems in aerospace structures.

[0006] Based on existing technology, there must be some aerospace structural components made of light alloys, which are therefore metallic materials, used in the fuselage.

[0007] The use of these metal components and their assemblies in contact with composite material structures can cause electrical coupling problems and associated risks of metal corrosion, necessitating increased inspection levels. This will increase the total cost for the manufacturers of these components, and thus contribute to an increase in the overall cost for the airline.

[0008] Therefore, these structural components need to be manufactured using composite materials.

[0009] The use of composite materials can reduce the overall weight of the aircraft while achieving a very robust structure.

[0010] In order to manufacture the above-mentioned structural elements, multiple layers of uncured or pre-cured composite materials are placed on a molding tool of appropriate shape, depending on the shape to be given to the structural elements.

[0011] Composite materials are typically fibrous materials. In particular, each layer is usually composed of a thermosetting (resin) matrix prepreg reinforced with various fibers such as carbon fiber, aramid fiber, and glass fiber.

[0012] These layers are then laminated together onto the molding tool.

[0013] After lamination, a molding process is typically performed on a molding die with the aid of a vacuum: in this way, the layers are compacted and given the desired shape of the structural element (e.g., T, Z, C, Ω (omega) profiles, etc.).

[0014] The resulting components are then cured by applying high pressure and temperature to a curing mold to cure the composite material and press the layers together.

[0015] Known composite structural elements extend along a straight or curved longitudinal direction and have a Z-shaped cross section relative to the longitudinal direction (i.e., have a Z-shaped profile). The structural element is, for example, a beam, stringer, wing beam, etc., and has: a central portion that defines the web of the structural element; and two ends that are arranged on opposite sides of the web and define two corresponding wings or flanges that extend perpendicular to the web and in opposite directions to each other, thereby precisely defining the Z-shaped profile.

[0016] In this field, there is a need to produce composite material structural elements with Z-shaped profiles through easily automated operations, preferably through automated operations without the need for any human assistance from operators. Summary of the Invention

[0017] The object of the present invention is to provide a method for manufacturing structural elements of composite materials that extend along a straight or curved longitudinal direction and have a Z-shaped cross section relative to that longitudinal direction. This method can meet the above-mentioned needs related to structural elements of composite materials having known types of Z-shaped cross sections in a simple and economical manner.

[0018] According to the present invention, this objective is achieved by the method for manufacturing structural elements of composite materials having a Z-shaped cross-section as described in claim 1.

[0019] Another object of the present invention is to provide an apparatus for manufacturing structural elements of composite materials that extend along a straight or curved longitudinal direction and have a Z-shaped cross section relative to that longitudinal direction, the apparatus being able to meet the aforementioned needs related to structural elements of composite materials having known types of Z-shaped cross sections in a simple and economical manner.

[0020] According to the present invention, this objective is achieved by the apparatus for manufacturing structural elements of composite materials having a Z-shaped cross-section as described in claim 8. Attached Figure Description

[0021] To better understand the invention, some preferred, rather than limiting, embodiments are described below by way of example and with the aid of the accompanying drawings, in which:

[0022] - Figure 1 This is a perspective view of a part of an apparatus used to manufacture structural elements of composite materials with a Z-shaped profile; some parts have been removed for clarity.

[0023] - Figure 2 It shows the way Figure 1 A three-dimensional view of a composite material structural element with a Z-shaped profile obtained by the equipment in the image;

[0024] - Figure 3 yes Figure 1 A schematic top view of the equipment under given operating conditions, enlarged to scale and with some parts removed for clarity;

[0025] - Figures 4A to 4C A schematic illustration of a first embodiment according to the present invention is shown. Figure 1 The equipment is shown in partial cross-sectional views under the following three operating conditions. Some parts have been removed for clarity.

[0026] - Figures 5A to 5C A second embodiment of the invention is illustrated schematically. Figure 1 The equipment is shown in partial cross-sectional views under the following three operating conditions. Some parts have been removed for clarity.

[0027] - Figure 6A and Figure 6B A schematic illustration of a third embodiment according to the present invention is shown. Figure 1 Partial cross-sectional views of the equipment under the subsequent two operating conditions, with some parts removed for clarity; and

[0028] - Figures 7A to 7C A schematic illustration of the fourth embodiment Figure 1 The device is shown in partial cross-sectional views under the following three operating conditions. Some parts have been removed for clarity. The fourth embodiment is shown for illustrative purposes only and is not included within the scope of the claimed invention, but is only intended to aid in understanding the invention. Detailed Implementation

[0029] Referring to the accompanying drawings, reference numeral 1 indicates an apparatus for manufacturing a structural element 2 of a composite material, which extends along the longitudinal direction D of a curve and has a Z-shaped cross-section relative to the longitudinal direction.

[0030] In particular, structural element 2 has a Z-shaped profile and is a multi-layered element used in the aviation field and forming part of the structure of an aircraft (not shown), such as beams, stringers, wing spars, etc. of an aircraft fuselage. This specification will refer to these structural elements without loss of generality.

[0031] In an embodiment not shown, structural element 2 may extend along a straight longitudinal direction.

[0032] Structural element 2 can be conveniently used to reinforce the aircraft fuselage to reduce the overall weight of the fuselage while obtaining a robust structure.

[0033] In the described example, the extension of structural element 2 along the longitudinal direction D is significantly greater than the extension in the other two directions orthogonal to the longitudinal direction D.

[0034] from Figure 2 As can be seen from this, structural element 2 has a Z-shaped cross-section (i.e., profile) in the longitudinal direction D, and structural element 2, except for Figure 2 Still Figure 4C , Figure 5C , Figure 6B and Figure 7C The final configuration shown includes a central web 2a and two wings or flanges 2b and 2c, which extend orthogonally from opposite ends of the web 2a in their respective opposite directions.

[0035] The longitudinal direction D has a non-zero radius of curvature R.

[0036] In an embodiment not shown, flanges 2b, 2c may extend from web 2a at a given final angle other than 90° (e.g., but not limited to 30°, 45°, 60°, 80°, 85°, etc.).

[0037] Specifically, the final angles of flanges 2b and 2c can be different from each other.

[0038] The structural element 2 described and illustrated herein is made of multiple layers 3 of composite material, each layer consisting of a prepreg having a polymer matrix (e.g., thermosetting resin) and preferably reinforced with fibers that may have different properties (e.g., carbon fibers and / or aramid fibers and / or glass fibers, etc.).

[0039] Alternatively, structural element 2 may also be made of a prepreg having a thermoplastic resin matrix, preferably reinforced with fibers of the type described above.

[0040] Preferably, the composite material is defined by a cured material or a pre-cured material.

[0041] In view of the above, each layer 3 is defined by a composite material comprising fibers dispersed in a thermosetting polymer matrix.

[0042] Figure 2 The structural element 2 in its final configuration, obtained through device 1, is shown.

[0043] The equipment 1 includes a molding die with a forming part 4.

[0044] refer to Figure 1 , Figure 3 and Figures 4A to 4C The structural element 2 is obtained by arranging multiple of the aforementioned layers 3 on a composite material, particularly on the forming part 4 of the molding die, in an automatically moving manner (e.g., controlled automatically by means of a programmable robot 20).

[0045] Specifically, the robotic arm 20 is configured to automatically arrange each layer of fiber composite material onto the forming part in a predetermined direction, conveniently and layer by layer.

[0046] More accurately, such as Figure 3 As can be seen, the robotic arm 20 is arranged on the forming part 4 in a predetermined sequence during use as follows:

[0047] -Fiber material layer 3a, which is oriented at 0° along the longitudinal direction D (of the curve), that is, oriented parallel to the longitudinal direction D;

[0048] -Fiber material layer 3b, which is arranged in an orientation at 45° relative to the longitudinal direction D;

[0049] -Fiber material layer 3c, which is arranged at an orientation of -45° relative to the longitudinal direction D, i.e., an orientation perpendicular to the orientation of layer 3b; and

[0050] -Fiber material layer 3d, which is arranged in an orientation at 90° relative to the longitudinal direction D.

[0051] In an alternative embodiment not shown, the arrangement of layer 3 can be performed manually by an operator.

[0052] In the described example, the so-called “manipulation” of these fibers can be achieved by using a robotic arm 20 to place the layers 3 (i.e., the fibers of the composite material) in a predetermined orientation, which is particularly advantageous when the longitudinal direction D of the structural element 2 has a non-zero radius of curvature R (i.e., bending). Specifically, the fibers of layer 3a at 0° are directly laminated into corresponding strips on the forming portion 4, each strip defining a continuous “monopiece” with a non-zero radius of curvature R.

[0053] In this way, the fibers can be arranged directly and continuously by bending them, rather than in a "broken" and discontinuous manner. From the viewpoint of the mechanical properties of structural element 2, this results in a significant improvement because there are no connecting parts between the fibers.

[0054] Conveniently, the structural element 2 includes a plurality of layers 3, which include layers 3a, 3b, 3c and 3d stacked on top of each other according to a predetermined pattern.

[0055] Once these layers are arranged on the forming portion 4, the layers 3 are automatically (e.g., by the aforementioned robotic arm) laminated together on the forming portion 4, such that ( Figure 4A ):

[0056] - The web 2a is arranged at least partially in the final configuration of the web;

[0057] - The first flange 2b is arranged in the final configuration of the first flange, that is, relative to the web 2a (more precisely, relative to the position of the web 2a arranged in the final configuration of the web), at a given final angle, preferably orthogonally, to the final configuration of the first flange; and

[0058] - The second flange 2c is arranged at an initial angle relative to the web 2a (more precisely, relative to the portion of the web 2a arranged in the final configuration of the web) to form the initial configuration of the second flange. This initial angle is different from and greater than the relative final angle, preferably not equal to 90° but greater than 90° (non-right angle).

[0059] exist Figure 4A In the example shown, the web 2a is fully arranged in its final configuration, and the second flange 2c is arranged at a 180° angle relative to the web 2a. More precisely, the second flange 2c defines the extension of the web 2a.

[0060] In other words, layer 3 is initially arranged on the forming portion 4 for lamination to form an L-shaped profile, the short side of which is defined by the first flange 2b, while the long side is defined by the web 2a and the second flange 2c.

[0061] Equipment 1, especially the molding die, includes a fixed part 5 and a movable part 6 that is movable relative to the fixed part 5.

[0062] The fixed portion 5 and the movable portion 6 together define the molded portion 4; more precisely, the molded portion 4 is partially defined by the outer molded surface of the fixed portion 5 and partially by the outer molded surface of the movable portion 6.

[0063] like Figure 4A and Figure 4B As can be seen, during use, layer 3 is laminated, so that the second flange 2c is arranged at the movable part 6.

[0064] In other words, the portion of layer 3 that constitutes the second flange 2c is arranged such that the portion is supported by the aforementioned external shaped surface of the movable portion 6.

[0065] Device 1 includes an actuator 7 configured preferably to automatically drive the movable part 6 relative to the fixed part 5 from a rest position. Figure 4A and Figure 4B Move to the curved position ( Figure 4C ).

[0066] Specifically, the device 1 includes a control unit (not shown) configured to automatically drive the movable part 6 from a stationary position to a bent position.

[0067] Advantageously, the movable portion 6 is configured to move from a stationary position to a bent position so that the second flange 2c moves from the initial configuration, in particular, bends to the final configuration, i.e., a configuration that defines the aforementioned final angle, preferably right angle (90°), with the web 2a.

[0068] More precisely, the movable part 6 is adapted to push the second flange 2c so as to automatically bend the second flange from the initial configuration to the final configuration.

[0069] In this way, a composite material structural element 2 with a Z-shaped profile is obtained in a simple, fast, and economical manner, preferably in a fully automated manner, by automatically moving the movable part 6 from a static position to a curved position without any human intervention. Figure 4C ).

[0070] According to this preferred embodiment, the movable portion 6 is adapted to translate linearly relative to the fixed portion 5.

[0071] Therefore, the actuator device 7 includes:

[0072] - Piston 8, which is, for example, a hydrodynamic piston (pneumatic, hydraulic, or oil-pressure), is fixed to one end of the movable part 6 opposite to the relevant external molded surface; and

[0073] -Guide-sliding system 10, which is configured to guide movable portion 6 to define linear translation of movable portion.

[0074] Alternatively, the actuator device 7 may include an electric actuator, such as a linear motor (not shown), defined by the guide-slide system 10.

[0075] In use, the piston 8 is actuable, thereby driving a linear translational motion from a rest position to a bent position guided by the guide-sliding system 10 of the movable part 6.

[0076] Conveniently, the actuation of piston 8 is automatically controlled by the control unit.

[0077] Alternatively, piston 8 can be manually driven by the operator.

[0078] Preferably, the device 1 includes an infrared device, such as at least one infrared lamp which is known in itself and not described or shown in detail, and is configured to emit infrared radiation toward layer 3 during the lamination operation, particularly during the subsequent molding operation, thereby reducing the tackiness of the resin in the prepreg material and causing layers 3 to slide together. In this way, wrinkling is avoided during the molding process, particularly during the bending of the second flange 2c.

[0079] In one embodiment, the infrared device is carried by a robotic arm 20.

[0080] Conveniently, the device 1 also includes an abutment 11, which can be in a rest position (not shown) and a compressed position relative to the plurality of layers 3. Figure 4B The web plate 2a is shifted between the abutment body 11 and the forming part 4 (i.e. the forming mold) so that it is inserted between the abutment body 11 and the forming part 4 (i.e. the forming mold).

[0081] Specifically, the abutment body 11 is configured to abut against the web plate 2a.

[0082] In use, the aforementioned control unit drives the abutment 11 to a compression position to at least compact the web 2a.

[0083] Conveniently, the second flange 2c is displaced (bent) by the movable part 6 until the second flange 2c abuts against the abutment body 11, as shown. Figure 4B As can be seen in the text.

[0084] In this way, the second flange 2c can be bent more effectively, thereby ensuring the correct final angle of the second flange 2c relative to the web 2a, especially the aforementioned 90° angle.

[0085] Preferably, once the lamination and molding of the structural element 2 are completed according to the above method, the structural element 2 is arranged in a curing device or co-curing device (which is known in itself and not shown) in use and according to a known method (not described in detail) to perform at least one curing or co-curing cycle.

[0086] More specifically, structural element 2 is inserted into a vacuum bag and placed in a curing or co-curing device (usually an autoclave) to withstand a certain pressure and a certain temperature (known in industry).

[0087] In view of the above, the polymerization cycle of structural element 2 is carried out.

[0088] If the matrix resin is thermoplastic, one or more “consolidation” cycles are performed according to known methods not described in detail.

[0089] refer to Figure 5A , Figure 5B and Figure 5C Reference numeral 1' indicates an apparatus for manufacturing a structural element 2 of a composite material having a Z-shaped cross-section (profile) according to a second embodiment of the present invention.

[0090] Since device 1' is similar to device 1 in structure and function, the following description will only focus on the differences between device 1' and device 1, and where possible, the same reference numerals will be used to denote the corresponding parts and components.

[0091] Specifically, the device 1' differs from the device 1 in that the movable part 6 is hinged to the fixed part 5 via a hinge 12, and the device 1' includes an actuator device 7' configured to move the movable part 6 relative to the fixed part 5 from a rest position to a bent position in a pivoting manner relative to the hinge 12.

[0092] In the described example, the actuator device 7' includes a piston 8', which is, for example, a hydrodynamic piston (pneumatic, hydraulic, or oil pressure) fixed to one end of the movable portion 6 opposite to the associated external shaped surface.

[0093] Piston 8' is configured to be driven automatically by the control unit.

[0094] Alternatively, piston 8' can be manually driven by the operator.

[0095] In view of the above, the movable part 6 is adapted (preferably automatically) to move between a rest position and a bent position by means of the piston 8', thereby performing a rotation about the hinge 12.

[0096] In this way, the bending of the second flange 2c in its final configuration can be achieved with a simpler structure and in a more efficient manner than with device 1, since the latter configuration does not require the guide-sliding system 10.

[0097] refer to Figure 6A and Figure 6B Reference numeral 1'' indicates an apparatus for manufacturing a structural element 2 of a composite material having a Z-shaped cross-section (profile) according to a third embodiment of the present invention.

[0098] Since device 1'' is similar to device 1' in structure and function, the following description will only focus on the differences between device 1'' and device 1', and where possible, the same reference numerals will be used to denote the corresponding parts and components.

[0099] Specifically, the difference between device 1'' and device 1' is that device 1'' includes an elastic reset device 7'', which defines the aforementioned actuator device, is inserted between the fixed part 5 and the movable part 6, and is configured to preferably automatically release from the deformed position to the undeformed position to drive the movable part 6 preferably automatically from the rest position to the bent position.

[0100] Specifically, the elastic reset device 7'' includes a spring 8'', which is preferably a helical spring, with its first end fixed to one end of the movable part 6 opposite to the relevant external molded surface and its second end fixed to the fixed part 5.

[0101] During the lamination of layer 3 on the forming part 4, spring 8'' is compressed in the deformed position to keep the movable part 6 in the stationary position.

[0102] In use, spring 8'' can be released, preferably automatically from the compressed deformation position via a command from the control unit. Figure 6A Released to the extended, undeformed position ( Figure 6B This allows the movable part 6 to move from a stationary position to a bent position, thereby determining the bending of the second flange 2c.

[0103] Alternatively, spring 8'' can be manually driven by the operator.

[0104] This configuration makes it possible to obtain a simpler system for driving the movement of the moving part 6 than the system of the previously described embodiment.

[0105] Conveniently, the difference between device 1'' and device 1' is that the movable part 6 is placed at an angle other than 180° relative to the fixed part 5 in its initial static position, in particular at an angle greater than 90° and less than 180°.

[0106] like Figure 6B As shown, this allows layer 3 to be laminated onto the shaped portion 4, such that the second flange 2c is positioned at an angle different from 180° relative to the web 2a in its initial configuration, particularly at an angle greater than 90° and less than 180° relative to the web 2a.

[0107] This specific arrangement means that the bending of the second flange 2c has already been "initiated" or preliminarily performed in some way during lamination by the robotic arm 20. This has another advantage: during the actual bending of the second flange 2c by the movable part 6, the second flange 2c exhibits the introduction of bending and is more easily adapted to bending.

[0108] Furthermore, due to this construction, the forming part 4 (i.e., the mold) is particularly suitable for automatic lamination, that is, to be performed automatically by the robot arm 20.

[0109] refer to Figure 7A , Figure 7B and Figure 7C Reference numeral 1''' indicates an apparatus for manufacturing a structural element 2 of a composite material having a Z-shaped cross-section (profile) according to a fourth embodiment. The fourth embodiment is shown by way of example only and is not included within the scope of the claimed invention, but is intended to aid in understanding the invention. Specifically, the fourth embodiment is not included within the scope of the independent claims.

[0110] Since device 1''' is similar to device 1 in structure and function, the following description will only focus on the differences between device 1''' and device 1, and where possible, the same reference numerals will be used to denote the corresponding parts and components.

[0111] Specifically, device 1''' differs from device 1 in that: device 1''' includes an insert 13, the insert 13 defining a movable portion 6, and the insert is configured to be arranged in an insertion position between the forming portion 4 and the plurality of layers 3 to support at least a portion of the second flange 2c in its initial configuration during the aforementioned lamination, preferably supporting the entire second flange 2c. Figure 7A ).

[0112] The insert 13 can be automatically (e.g., by the aforementioned robotic arm) moved during use from the insertion position defining the aforementioned rest position to an external position relative to the plurality of layers 3, such that the second flange 2c is inserted between the insert 13 and the formed portion 4. Figure 7B ).

[0113] The insert 13 can be moved from an external position to a compression position defining the aforementioned bending position to press the second flange 2c against the formed portion and move the second flange from the initial configuration to the final configuration. Figure 7C (As shown in the image).

[0114] Preferably, the insert 13 can be moved automatically (e.g., by a robotic arm 20), in which case the robotic arm 20 defines the aforementioned actuator device.

[0115] Alternatively, the insert 13 can be manually moved from the insertion position to an external position by the operator.

[0116] This particular embodiment has another advantage: due to the presence of the insert 13 inserted between the forming portion 4 and the layer 3, the layer 3 itself can also be mounted on the mold by the robot arm 20 (i.e., in a shape like...). Figure 7A , Figure 7B and Figure 7C The "Z" shape shown in the figure is laminated on the forming part 4.

[0117] Without insert 13, laminating layer 3 with the compaction roller of robot 20 (which is known but not shown in detail) at an inside right angle, i.e., at the angle from which the second flange 2c extends from the web 2a, is actually complex.

[0118] Therefore, due to the presence of insert 13, structural elements 2 with Z-shaped profiles can be obtained automatically using common Z-shaped molds (forming part 4), thereby realizing these structural elements in the automatic lamination process by the automatic robot 20.

[0119] Conveniently, in use, the laminated layer 3 and the insert 13 displaced to the external position are accommodated in a vacuum chamber 14, which is defined between the vacuum bag 15 (of a known type and not described in detail) and the forming part 4 (and thus between the vacuum bag 15 and the forming mold).

[0120] At this time, a vacuum is applied in the vacuum chamber 14 to move the insert 13 from the external position to the compressed position, thereby bending the second flange 2c, and optionally bending a portion of the web 2a of the initial configuration from the initial configuration to the final configuration.

[0121] From an examination of the features of the devices 1, 1', 1'' and the manufacturing method implemented according to the present invention, the advantages that these devices and manufacturing methods allow to obtain are obvious.

[0122] In particular, the apparatus 1, 1', 1'' and manufacturing method according to the invention allow for the production of composite material structural elements 2 with Z-shaped cross sections (profiles) through easily automated operations, thereby increasing the degree of automation in the manufacturing process of the structural element 2, while simultaneously allowing the process to be implemented by human intervention by an operator when deemed appropriate.

[0123] In fact, the actuator devices 7, 7', 7'' configured to move the movable part 6 can be driven automatically or manually by the operator.

[0124] This results in extremely flexible manufacturing processes.

[0125] Furthermore, the structure of equipment 1, 1', 1'' is greatly simplified compared to known automated manufacturing equipment, which is typically bulky and expensive.

[0126] Obviously, the devices 1, 1', 1'' and methods described and illustrated herein can be modified and varied without departing from the scope of protection defined by the claims.

[0127] In particular, the movable part 6 can be moved manually by the operator.

Claims

1. A method for manufacturing a structural element (2) of a composite material, the structural element extending along a straight or curved longitudinal direction (D) having a Z-shaped cross section relative to said longitudinal direction (D), and the structural element comprising, in its final configuration, a central web (2a) and two flanges (2b, 2c) extending from opposite ends of said web (2a) in mutually opposite directions at a given final angle; the method comprising the steps of: a) Arrange multiple layers (3) of the composite material on the forming part (4) of the molding die; b) The plurality of layers (3) are laminated onto the forming portion (4) such that the web (2a) is at least partially arranged in its final configuration, such that the first flange (2b) is arranged in the final configuration of the web (2a) relative to the portion of the web (2a) arranged in the final configuration of the web at the final angle, and such that the second flange (2c) is arranged in the initial configuration of the second flange relative to the portion of the web (2a) arranged in the final configuration of the web at an initial angle different from and greater than the final angle. c) Moving the movable part (6) of the molding die from a rest position to a bent position, the movable part being movable relative to the fixed part (5) of the molding die, the fixed part (5) and the movable part (6) together defining the forming part (4), the forming part (4) being partially defined by the outer forming surface of the fixed part (5) and partially defined by the outer forming surface of the movable part (6); d) Displace the second flange (2c) from the initial configuration to the final configuration, in which the second flange is at the final angle relative to a portion of the web (2a) arranged as a web. Lamination step b) is performed by arranging the second flange (2c) at the movable portion (6). Shift step d) is performed by moving step c). Arrangement step a) is performed by positioning the second flange (2c) at the movable part (6). Furthermore, the moving step c) includes releasing the elastic reset device (8'') from the deformed state to the undeformed state.

2. The method according to claim 1, wherein, The moving step c) includes the following steps: e) Push the second flange (2c) through the movable part (6); Furthermore, the shifting step d) includes the following steps: f) The second flange (2c) is folded from the initial configuration to the final configuration by moving the movable part (6) from the stationary position to the folded position.

3. The method according to claim 1, wherein, The moving step c) includes driving a hydrodynamic actuator or an electric actuator (8, 8').

4. The method according to claim 1, further comprising the following step: h) Arrange the abutment (11) against the plurality of layers (3) such that at least the web (2a) is inserted between the abutment (11) and the forming portion (4); as well as i) Move the abutment (11) toward the forming part (4) to at least compact the web (2a). Furthermore, the displacement step d is performed by pushing the second flange (2c) with the aid of the movable part (6) until the second flange abuts against the abutting body (11).

5. An apparatus (1, 1', 1'') for manufacturing a structural element (2) of a composite material, the structural element extending along a straight or curved longitudinal direction (D) and having a Z-shaped cross section relative to said longitudinal direction (D), the structural element comprising a plurality of layers (3) of a composite material, and the structural element comprising, in its final configuration, a central web (2a) and two flanges (2b, 2c) extending from opposite ends of the web (2a) in their respective directions opposite to each other at a given final angle; The device (1, 1', 1'') includes a molding die having a forming portion (4) configured to support the plurality of layers (3) of the composite material, the plurality of layers being arranged on the forming portion (4) and laminated together on the forming portion (4) such that, in use, the web (2a) is at least partially arranged in its final configuration such that a first flange (2b) is arranged in the final configuration of the web (2a) relative to the portion of the web (2a) arranged in the final configuration of the web at the final angle, and a second flange (2c) is arranged in the initial configuration of the second flange relative to the portion of the web (2a) arranged in the final configuration of the web at an initial angle different from and greater than the final angle. The molding die of the device (1, 1', 1'') includes a fixed portion (5) and a movable portion (6) movable relative to the fixed portion (5), the fixed portion (5) and the movable portion (6) together defining the molding portion (4), the molding portion (4) being partially defined by the outer molding surface of the fixed portion (5) and partially defined by the outer molding surface of the movable portion (6); The second flange (2c) is configured to be arranged and laminated on the movable portion (6); The movable portion (6) is configured to move from a rest position to a bent position to move the second flange (2c) from the initial configuration to the final configuration. The device further includes an elastic reset device (8'') inserted between the fixed part (5) and the movable part (6), and the elastic reset device is configured to release from the deformed position to the undeformed position to drive the movable part (6) from the stationary position to the bent position.

6. The device (1, 1') according to claim 5, further comprising a hydrodynamic actuator or an electric actuator (8, 8') that is drivable to move the movable portion (6) from the rest position to the bent position.

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