METHOD FOR MANUFACTURING A COMPOSITE PLATE

Description

[0001] The invention relates to a method for manufacturing a composite panel.

[0002] Such a panel can notably form a seat component, for example an airplane seat.

[0003] Such a composite panel can be formed from a stack of layers, usually made with fibers, between which is a structural element that defines the outline of the panel.

[0004] Traditional methods are based on stacking the panels and then manufacturing them in a mold. However, after manufacturing the panel, these traditional methods require cutting to define the precise shape of the panel's outline.

[0005] This cutting step requires specific tools and therefore additional time.

[0006] As a result, manufacturers are seeking solutions to simplify the production of such panels, both for reasons of cost and time, while obtaining a composite panel with clean contours.

[0007] Document WO 2016 / 087346 A1 describes a method for manufacturing a composite panel comprising a cord surrounding the panel and several composite layers, at least one of which is wound around the cord. Similar methods, such as those proposed by WO 83 / 03794 A1, GB 2 212 436 A, or GB 1366 773 A, can be used, in particular, for the manufacture of rackets, especially tennis rackets.

[0008] One objective of the invention is to address the aforementioned problem.

[0009] To this end, the invention proposes a method for manufacturing a composite panel according to claim 1.

[0010] This process may also exhibit at least one of the following characteristics, taken alone or in combination:In the case where step c 1) is implemented, a portion of the first layer is folded over the structural element between steps b) and c 1), this portion including said peripheral contour; before or after folding the relevant portion of the first layer, but preferably before, an adhesive is applied to said portion of the first layer including said peripheral contour; the material forming the first layer is selected from carbon fibers, glass fibers, or Kevlar® fibers; the material forming the second layer is selected from carbon fibers, glass fibers, or Kevlar® fibers; the thermoplastic resin injected in step d) is selected from polyurethane, polyetherimide, or polyamide; the thermosetting resin injected in step d) is selected from an epoxy, phenolic, or urethane type thermosetting resin; step e) is accompanied by heating;At the end of step e), a post-curing step f) is planned, advantageously carried out in the mold used to obtain the panel; the structural element placed during step b) on the first layer has the desired shape of the peripheral contour of the composite panel; the structural element is chosen from a set of woven fibers, for example in the form of a braid; a set of non-woven fibers; a thermosetting or thermoplastic resin, in solid form; a syntactic foam; the structural element consists of a set of woven or non-woven fibers, said fibers being chosen from carbon fibers, glass fibers or Kevlar® fibers; the set of woven or non-woven fibers is pre-impregnated with a thermoplastic or thermosetting resin; the set of woven or non-woven fibers is pre-impregnated with a thermoplastic resin chosen from polyurethane, polyetherimide, or polyamide;The woven or non-woven fiber assembly is pre-impregnated with a thermosetting resin chosen from an epoxy, phenolic, or urethane type; the woven fiber assembly is in the form of a braid. The structural element is an epoxy type thermosetting resin.

[0011] The invention will be better understood and other objects, advantages and features thereof will become more apparent upon reading the following description, which is made with reference to the following attached figures: There figure 1 which includes the figures 1(a) à 1(e) , represents a composite panel, in this case an aircraft seat backrest, obtained according to a first manufacturing process according to the invention; The figure 2 which includes the figures 2(a) à 2(d) , represents a composite panel, in this case an aircraft seat armrest, obtained according to a second manufacturing process according to the invention; The figure 3 which includes the figures 3(a) à 3(e) , represents the structure obtained at the end of different manufacturing stages, according to the invention, of a composite panel.

[0012] A first method for manufacturing a PC composite panel according to the invention is described below.

[0013] This first embodiment is particularly well suited for manufacturing a composite panel intended to form a seat component such as a backrest or headrest for which, at a given mass, significant mechanical resistance is desirable.

[0014] The process includes the following steps: provide a first layer NP1 of a dry, woven or non-woven material, said first layer defining a peripheral contour CP; arrange a structural element ES, namely either a set of woven fibers, for example in the form of a braid EST, or a set of non-woven fibers EF, within the peripheral contour CP of said first layer NP1, over at least a part of this peripheral contour; then: either arrange a second layer NP2 of a dry, woven or non-woven material, so that said second layer NP2 covers both the first layer NP1 and the structural element ES, or fold a part of the first layer NP1, this part having the peripheral contour CP, to cover the structural element ES and then arrange a second layer NP2 of a dry, woven or non-woven material, so that said second layer NP2 covers the first layer NP1, but not the structural element ES; the stack thus formed at the end of this last step being either already in a mold or outside of a mold and then placed in said mold, inject a thermoplastic or thermosetting resin into the mold, in particular to impregnate the NP1, NP2 layers; press the assembly into the mold to obtain the composite panel.

[0015] The pressing stage may be accompanied by heating.

[0016] By "dry" material (NP1, NP2 layers), it is important to understand that the layer is not a "prepreg." This is important because an NP1, NP2 layer made of a dry material, whether woven or non-woven, exhibits high deformability, which greatly facilitates its handling and the layering of another layer and / or the structural element. Indeed, with "prepreg" layers, layering, while possible, is not easy and results in a visible excess thickness on the final composite panel; this is not the case with layers made of "dry" material, since the resin injected into the mold allows for better smoothing of the difference in level, particularly in the case of a mold made of two corresponding parts. This is all the more true when, for the intended applications, the composite panel to be manufactured has a complex shape. Compared to a "prepreg," there are therefore savings in installation time and consequently in costs.Furthermore, since the placement of a dry fabric layer is easier than with a "prepreg", the mechanical strength of the resulting composite part is better for such a complex-shaped composite panel.

[0017] An example of a composite panel obtained through this manufacturing process is shown on the figure 1 In this case, the structural element is an EST braid; that is, a specific type of woven fiber. Furthermore, for the sake of simplicity, the EST braid will be considered representative of the observations that could be made for any woven fiber.

[0018] More specifically, the figures 1(a) et 1(b) represent respectively according to a general perspective view and according to a cross-sectional view on Fig. 1(b), the composite panel obtained at the end of the manufacturing process in the case where the second layer NP2 covers both the first layer NP1 and the structural element ES, in this case a braid EST.

[0019] Furthermore, on the figure 1(b) In particular, we can observe the non-zero distance d separating the braid EST from the peripheral contour CP of the first layer NP1. This non-zero distance d shows that the braid EST is indeed, during manufacturing, positioned within the peripheral contour CP of said first layer NP1. Furthermore, in the specific case shown in the figures, the braid is present within the peripheral contour CP of the first layer NP1, along the entire perimeter of the first layer NP1.

[0020] Of course, the case presented in support of the figures 1(a) et 1(b) is applicable in the case where the braid is replaced by non-woven fibers.

[0021] It should be noted that an additional step can be taken, after placing the braid EST or the woven fiber assembly EF on the first layer NP1 and before covering it with the second layer NP2. In this additional step, a portion of the first layer NP1 is folded around the braid EST or the fiber assembly EF, this portion including the peripheral contour CP. Before folding this portion of the first layer NP1, the peripheral contour CP is therefore located externally to the braid EST or the fiber assembly EF; this is no longer the case after folding.

[0022] This is what is represented on the figure 1(c) This case of reversal of the first layer NP1 corresponds, for the second embodiment which will be described later, to the diagram of the figure 2(c) .

[0023] This allows for better retention of the EST braid or, as the case may be, the EF woven fiber assembly, before the stack formed by the first layer NP1, the EST braid or the EF woven fiber assembly, and the second layer NP2 is pressurized in the mold. In particular, there is less risk during manufacturing of the fibers at the end of the NP1 layer becoming trapped in the mold. Furthermore, the mechanical strength of the finished part is improved, while limiting the area of ​​excess thickness to three layers (NP1, NP1, NP2). It should be noted that this additional step is not mandatory, but is sometimes very advantageous.

[0024] However, when this additional folding step is considered, it is advantageous, either before or after folding, but preferably before, to apply an adhesive to the portion of the first layer NP1 containing the peripheral contour CP. This improves the adhesion of the folded portion of the first layer NP1 to the braid EST or the woven fiber assembly EF, thus allowing the second layer NP2 to be positioned correctly, ensuring that the relative positioning of the first layer NP1 and the braid EST or the woven fiber assembly EF has not changed.

[0025] On the figure 1(d) , we have represented according to a cross-sectional view, the positioning in the mold M, before pressing and heating of the different components of the composite panel to be manufactured, in the case where the second layer NP2 only covers the first layer NP1, without covering the structural element, in this case a braid EST.

[0026] In relation to the implementation of the figure 1(c) The advantages provided by reversing the first layer NP1 are retained. Furthermore, the installation of the second layer NP2 can be easier. However, the area of ​​increased thickness with three layers (NP1, NP1, NP2) is more extensive.

[0027] The choice of the configuration of the figure 1(b), 1(c) ou 1(d) will depend on the intended application.

[0028] Here, the non-zero distance d separating the braid EST from the peripheral contour CP of the first layer NP1 must be sufficient so that folding a portion of the first layer NP1 allows the braid to be covered. On the figure 1(d) We can note that this distance d is equal to d = d1 + d2 + d3. This distance d defines the part PR of the first layer NP1 which is folded.

[0029] Of course, the case presented on the figure 1(d) is applicable when the braid EST is replaced by an assembly EF of non-woven fibers.

[0030] A set of nonwoven EF fibers is schematically represented, in a cross-sectional view, on the figure 1(e) . There figure 1(e) simply corresponds to the case of the figure 1(b) but with non-woven fibers. The use of an EST braid or, as the case may be, an EF assembly of non-woven fibers makes it possible to provide the desired mechanical resistance to the PC composite panel finally produced at the end of the manufacturing process.

[0031] The material forming the first layer NP1 can be chosen from carbon fibers, glass fibers or Kevlar® fibers.

[0032] Furthermore, the material forming the second layer NP2 can be chosen from carbon fibers, glass fibers or Kevlar® fibers.

[0033] In particular, a second layer NP2 can be made from the same material as the first layer NP1. Specifically, the second layer NP2 can be made of carbon fibers, just like the first layer NP1.

[0034] Regardless of the type of material considered, carbon fibers can, for example, be found in the form of a carbon fiber fabric.

[0035] With regard to the structural element ES, the fibers of the EST braid (woven fibers) or the non-woven fibers can notably be chosen from carbon fibers, glass fibers or Kevlar ® fibers.

[0036] The EST braid, or the EF assembly of non-woven fibers, can be pre-impregnated with a thermoplastic or thermosetting resin.

[0037] The thermoplastic resin can then be chosen from polyurethane (PU), polyetherimide (PEI), or polyamide (PA). The thermosetting resin can be chosen from an epoxy, phenolic, or urethane type.

[0038] The EST braid or, as the case may be, the EF set of non-woven fibers, is intended to define the shape of the peripheral contour of the composite panel, namely here the seat component to be manufactured.

[0039] To this end, it can be anticipated that the braid EST, or as the case may be, the EF assembly of non-woven fibers, already possesses the desired contour shape for the composite panel when it is positioned on the first layer NP1. This can be achieved in a specific mold, which is used to pre-impregnate the braid EST, or the EF assembly of non-woven fibers, with thermoplastic or thermosetting resin. In this case, the manufacturing steps of the PC composite panel described previously and carried out in the mold (resin injection, particularly to impregnate the layers; pressure and possibly temperature control) will only serve to ensure the mechanical bond between the first layer NP1, the braid EST or the EF assembly of non-woven fibers, and the second layer NP2 to form the PC composite panel, the contour shape having been defined previously.

[0040] Alternatively, the shaping of the braid EST, or, as the case may be, the assembly EF of nonwoven fibers, to that of the peripheral contour CP of the composite panel can be defined by the mold in the stack comprising the first layer NP1, the braid EST, or, as the case may be, the assembly EF of nonwoven fibers, and the second layer NP2, for its pressurization and possibly its heating to effectively obtain said composite panel PC. In this case, the braid EST, or, as the case may be, the assembly EF of nonwoven fibers, is advantageously not pre-impregnated before its positioning on the first layer NP1, to facilitate its shaping. The subsequent step of injecting thermoplastic or thermosetting resin is then used to impregnate the braid or the assembly of nonwoven fibers, the shaping of the structural element ES to the peripheral contour of the composite panel then taking place at the time of pressurization in the mold.

[0041] The solution of preforming the braid EST or, as the case may be, the assembly EF of non-woven fibers, in a specific mold is easier to implement than the solution of forming the braid with the other components intended to form the composite panel.

[0042] When the EST braid or the EF assembly of non-woven fibers is not impregnated with a thermoplastic or thermosetting resin before being placed on the first layer, the shape of the EST braid can be defined by that of the mold in the stack comprising the first layer NP1, the EST braid and the second layer NP2, for its pressurization and heating in order to effectively obtain said PC composite panel.

[0043] The resin injected into the mold, to impregnate the plies (but also the braid or the entire set of non-woven fibers when, in particular, these have not been pre-impregnated), can be a thermoplastic resin chosen from polyurethane (PU), polyetherimide (PEI), or polyamide (PA). For example, for polyetherimide (PEI), the injection is carried out, depending on the exact nature of the polyetherimide used, at a pressure between 70MPa and 125MPa and at a temperature between 350°C and 400°C (in liquid form).

[0044] Alternatively, the resin injected into the mold, to impregnate the layers in particular, can be a thermosetting resin chosen from among a thermosetting resin of the epoxy, phenolic or urethane type.

[0045] Typically, the step of pressing the resin-impregnated stack into the mold is carried out under the following pressure conditions: a pressure of at least 0.065 MPa (20 in-Hg). The temperature during pressing can range from ambient temperature (no heating) to several tens of degrees above ambient temperature (heating), depending on the chemical nature of the resin used.

[0046] Furthermore, it should be noted that the step of supplying the first layer NP1 may consist of supplying a plurality of stacked first layers. Similarly, the step of laying the second layer NP2 may consist of laying a plurality of stacked second layers, all covering both the first layer NP1 (or said plurality of first layers) and the braid EST or, as the case may be, the set of woven or non-woven fibers EF.

[0047] In addition, following the steps described above, post-curing can be planned, advantageously carried out in the mold in which the PC composite panel was formed, to adjust the mechanical properties of the component.

[0048] A second method for manufacturing a composite panel, in this case forming a seat component according to the invention, is described below.

[0049] This second embodiment is particularly well suited for manufacturing a composite panel intended to form a seat component such as a side panel of an armrest for which, for a given mass, the mechanical resistance may be less important than for a seat back for example.

[0050] In this case, the structural element ES is a thermoplastic or thermosetting ESR resin. In particular, but not exclusively, the resin used may be a thermosetting epoxy resin.

[0051] The panel manufacturing process then includes the following steps: provide a first layer NP'1 of a dry, woven or non-woven material, said first layer defining a peripheral contour; place a structural element ES, in this case either a thermoplastic ESR resin or a thermosetting resin, in solid form, or a syntactic foam MS, inside the peripheral contour CP' of said first layer, on at least a part of this peripheral contour, this structural element ES' having a shape intended to define the shape of the contour of said composite panel;then either place a second layer NP'2 of a dry, woven or non-woven material so that said second layer NP'2 covers both the first layer NP'1 and the structural element ES, or fold at least a part PR' of the first layer NP'1, this part including the peripheral contour CP', to cover the structural element and then place a second layer NP'2 of a dry, woven or non-woven material so that said second layer NP'2 only covers the first layer NP'1, without covering the structural element ES; the stack thus formed at the end of this last step being either already in a mold or out of a mold and then placed in said mold, inject a thermoplastic or thermosetting resin into the mold, in particular to impregnate the layers NP'1, NP'2; press the assembly in the mold to obtain the composite panel.

[0052] The pressing stage may be accompanied by heating.

[0053] By "dry" material (layers NP'1, NP'2), it should be understood that the layer is not a "prepreg". The advantages it provides are the same as those described in support of the first embodiment.

[0054] An example of a panel obtained through this manufacturing process is shown on the figure 2 , according to a general perspective view on the figure 2(a) and according to a cross-sectional view in Fig. 2(b), in the case where the structural element is an ESR resin. This ESR resin can notably be a thermosetting epoxy resin.

[0055] There figure 2(d) corresponds to the figure 2(b) , but in the case of MS syntactic foam. MS syntactic foam can for example be Airex ®< C70.90.

[0056] There figure 2(c) This shows more precisely the arrangement of the ESR resin and the layers, for this example. This corresponds to the case where the second layer NP'2 covers both the first layer NP'1 and the structural element ES, in this case a thermoplastic or thermosetting ESR resin or a syntactic MS foam.

[0057] Even more so, the figure 2(c) is a case in which an additional step has been implemented.

[0058] Indeed, it should be noted that an additional step can be planned, after placing the structural element ES, in this case the thermoplastic or thermosetting ESR resin, on the first layer NP'1 and before covering everything with the second layer NP'2, during which a portion PR' of the first layer NP'1 is folded over this thermoplastic or thermosetting ESR resin, this portion PR' having the aforementioned peripheral contour CP'. Before folding the first layer NP'1, this portion PR' is therefore located externally with respect to the thermoplastic or thermosetting ESR resin, but is no longer so after folding this first layer NP'1.

[0059] This allows the thermoplastic or thermosetting ESR resin to be held in place before the stack formed by the first layer NP'1, the thermoplastic or thermosetting ESR resin and the second layer NP'2 is pressurized in the mold. This is all the more advantageous as the resin, although solid when placed on the first layer, is relatively fragile, especially compared to a braid or more generally to a set of fibers.

[0060] Furthermore, the mechanical strength is then of better quality.

[0061] There figure 2(c) This schematically represents the stacking obtained in the vicinity of the peripheral contour CP' of the first layer NP'1 after folding the first layer NP'1 onto the thermoplastic or thermosetting ESR resin and after covering both this thermoplastic or thermosetting ESR resin and the first layer NP'1 with the second layer NP'2. On this figure 2(c) It should also be noted that the non-zero distance d, already defined with reference to the figure 1(b) or to the figure 1(c) corresponds, on the figure 2(c) à d = d1 + d2.

[0062] This clearly shows that the structural element ES, in this case the thermoplastic or thermosetting resin ESR, is located inside the peripheral contour CP' of the first layer NP'1. It also shows that the folded part PR' of the first layer NP'1 is the part located, before folding, external to the resin ESR, and whose total length is d 1 + d 2.

[0063] When this additional folding step is considered, as is the case on the figure 2(c) It is advantageous, before or after folding, but preferably before, to apply an adhesive to the part of the first layer containing the peripheral contour. This improves the adhesion of the PR' portion of the first folded layer against the thermoplastic or thermosetting ESR resin, and thus allows the second layer NP'2 to be positioned afterward, ensuring that the relative positioning of the first layer NP'1 and the thermoplastic or thermosetting ESR resin has not changed.

[0064] It should be noted that this additional step is not mandatory. Therefore, within the framework of this second embodiment, the configuration of the figure 1(b) . The thermoplastic or thermosetting ESR resin then simply replaces the EST braid.

[0065] Furthermore, in the variant where the second layer NP'2 only covers the first layer NP'1, but not the structural element ES, we find the configuration of the figure 1(c) explained for the first embodiment. The thermoplastic or thermosetting ESR resin (or, where applicable, the syntactic foam) then simply replaces the EST braid (or, where applicable, the set of fibers, woven or non-woven).

[0066] Of course, the comments made above in support of the figure 2 , are transposable in the case where the thermoplastic or thermosetting ESR resin is replaced by an MS syntactic foam.

[0067] The material forming the first layer NP'1 can be chosen from carbon fibers, glass fibers or Kevlar ® fibers.

[0068] The material forming the second layer NP'2 can be chosen from carbon fibers, glass fibers or Kevlar ® fibers.

[0069] In particular, a second layer NP'2 can be made from the same material as the first layer NP'1. Specifically, the second layer NP'2 can be made from carbon fibers, just like the first layer NP'1.

[0070] Here too, regardless of the layer considered, carbon fibers can, for example, be presented in the form of a carbon fiber fabric.

[0071] Similar to the case of the braid or the set of fibers, the solid thermoplastic or thermosetting ESR resin, or, as the case may be, the syntactic foam, then allows the shape of the outline of the composite PC panel to be manufactured to be defined.

[0072] In practice, it is expected that the thermoplastic or thermosetting ESR resin, or, as the case may be, the syntactic foam, already has the desired contour shape for the PC' composite panel when it is positioned on the first layer NP'1. This can be achieved in a specific mold. In this case, the composite panel manufacturing steps described previously and carried out in the mold (resin injection to impregnate the layers; pressure and temperature control) serve to ensure the mechanical bond between the first layer NP'1, the thermoplastic or thermosetting ESR resin or the MS syntactic foam, and the second layer NP'2 to form the PC' composite panel, the contour shape of which has been previously defined by shaping the resin or the syntactic foam in a specific mold.

[0073] The resin injected into the mold can be a thermoplastic resin chosen from polyurethane (PU), polyetherimide (PEI), or polyamide (PA). The injection conditions (pressure and temperature) are the same as those described for the first embodiment.

[0074] Alternatively, the resin injected into the mold can be a thermosetting resin chosen from among epoxy, phenolic or urethane type thermosetting resins.

[0075] The step of pressing the resin-impregnated stack into the mold is carried out under the same pressure conditions as those described previously for the first embodiment. The same applies to the temperature.

[0076] Furthermore, it should be noted that the step of supplying the first layer NP'1 may consist of supplying a plurality of stacked first layers. Similarly, the step of laying the second layer NP'2 may consist of laying a plurality of stacked second layers, all covering both the first layer NP'1 (or said plurality of first layers) and the thermoplastic or thermosetting ESR resin forming the structural element.

[0077] Furthermore, after obtaining the PC' composite panel, a post-curing process can be carried out, advantageously in the mold in which the composite panel was formed, to adjust the component's mechanical properties. In practice, there is then no need to remove the PC' composite panel from the mold, as the post-curing is achieved by heating the mold.

[0078] The application examples considered above relate to aircraft seat components. Of course, other applications, for example outside the aeronautical field, can be considered.

[0079] Example: a test was carried out to ensure the feasibility of a composite panel intended to form a side panel for an aircraft seat armrest.

[0080] A first woven carbon fiber sheet was supplied (Carbone Satin 94900 6K 5HS from BGF). It can be seen on the figure 3(a) .

[0081] Then, a thermosetting epoxy resin (MAGNOBOND ® < 77-4 A / B) was applied to the first layer in solid form. The result can be seen on the figure 3(b) The shape of the thermosetting epoxy resin was defined beforehand in a specific mold.

[0082] Next, the portion of the first layer containing the aforementioned peripheral contour was folded over the epoxy-type thermosetting resin. To help secure the first layer to the epoxy-type thermosetting resin, an adhesive (AIRTEC 2) was sprayed on. The result can be seen on the figure 3(c) .

[0083] Then, a second layer identical to the first in its composition (Carbone Satin 94900 6K 5HS from BGF) was deposited both on the first layer and on the epoxy-type thermosetting resin. The result can be seen on the figure 3(d) .

[0084] As can be seen in this example, the stacking of the figure 3(d) was carried out on a (lower) part of the mold.

[0085] A thermosetting resin, specifically EPOLAM 2015 SYSTEM resin from AXSON (Axson Technologies), was then injected into the mold. The injection of this resin was carried out at room temperature (23°C). To inject the resin, the mold was placed under vacuum (0.1 MPa) to draw the resin into the mold. For this purpose, the mold is equipped with an opening that allows a pump to create a vacuum.

[0086] Next, the assembly was held under vacuum (0.1 MPa) for 6 hours. This vacuum holding process involves pressurizing the stack placed in the pressure mold using the mold components. No heating was applied during this pressurization process, so the pressurization occurred at ambient temperature (23°C) within the mold.

[0087] Finally, a post-curing was then carried out for 24 hours at 80°C, under vacuum (0.1Mpa), in this case in the mold used to form the composite panel.

[0088] The finally obtained side panel of the armrest is shown on the figure 3(e) , inner side on the left and outer side on the right.

Claims

1. Process for manufacturing a composite panel (PC, PC'), said process comprising the following steps: a) providing at least one first ply (NP1, NP1') of a woven or nonwoven dry material, said first ply defining a peripheral contour (CP, CP'); b) placing a structuring element (ES; EST, EF, ESR) inside the peripheral contour of said first ply, on at least one portion of this peripheral contour; then c1) either placing at least one second ply (NP2, NP'2) of a woven or nonwoven dry material, such that said second ply covers both the first ply and the structuring element; c2) or folding over at least one portion (PR) of the first ply (NP1, NP'1), this portion comprising the peripheral contour (CP), to cover the structuring element (ES), then placing a second ply (NP2, NP'2) of a woven or nonwoven dry material, such that said second ply (NP2, NP'2) covers only the first ply (NP1, NP'1), without covering the structuring element (ES); the stack thus formed at the end of step c1) or c2) already being either in a mould or outside of a mould and thus placed in said mould, d) injecting a thermoplastic or thermosetting resin into the mould, in particular to impregnate the plies (NP1, NP'1; NP2, NP'2); e) pressing the assembly into the mould to obtain the composite panel.

2. Process according to claim 1, wherein, in the case where step c1) is implemented, between steps b) and c1), a portion (PR') of the first ply (NP1, NP1') is folded over on the structuring element (ES), this portion (PR') comprising said peripheral contour (CP).

3. Process according to one of the preceding claims, wherein, before or after the folding over of the portion in question of the first ply (NP1, NP'1), but preferably before, an adhesive is applied on said portion (PR, PR') of the first ply (NP1, NP'1) comprising said peripheral contour (CP, CP').

4. Process according to one of the preceding claims, wherein the material forming the first ply (NP1, NP'1) is selected from carbon fibres, glass fibres or Kevlar® fibres.

5. Process according to one of the claims, wherein the material forming the second ply (NP2, NP'2) is selected from carbon fibres, glass fibres or Kevlar® fibres.

6. Process according to one of the preceding claims, wherein the thermoplastic resin injected in step d) is selected from polyurethane (PU), polyetherimide (PEI), or polyamide (PA).

7. Process according to one of claims 1 to 5, wherein the thermosetting resin injected in step d) is selected from a thermosetting resin of the epoxide, phenolic or urethane type.

8. Process according to one of the preceding claims, wherein step e) is accompanied by heating.

9. Process according to one of the preceding claims, wherein, at the end of step e), a post-curing step f) is provided, advantageously carried out in the mould having made it possible to obtain the panel.

10. Process according to one of the preceding claims, wherein the structuring element (ES) placed during step b) on the first ply (NP1, NP'1) has the desired shape of the peripheral contour (CP) of the composite panel (PC).

11. Process according to one of the preceding claims, wherein the structuring element (ES) is selected from: - an assembly of woven fibres, for example, in the form of a braid (EST); - an assembly of nonwoven fibres (EF); - a thermosetting or thermoplastic resin (ESR), in solid form; - a syntactic foam (MS).

12. Process according to the preceding claim, wherein the structuring element (ES) consists of an assembly of woven or nonwoven fibres, said fibres being selected from carbon fibres, glass fibres or Kevlar® fibres.

13. Process according to one of claims 10 or 11, wherein the assembly of woven or nonwoven fibres is pre-impregnated with a thermoplastic or thermosetting resin.

14. Process according to the preceding claim, wherein the assembly of woven or nonwoven fibres is pre-impregnated with a thermoplastic resin selected from polyurethane (PU), polyetherimide (PEI) or polyamide (PA).

15. Process according to one of claims 10 to 12, wherein the assembly of woven or nonwoven fibres is pre-impregnated with a thermosetting resin selected from a thermosetting resin of epoxide, phenolic or urethane type.

16. Process according to one of claims 10 to 13, wherein the assembly of woven fibres is presented in the form of a braid (EST).

17. Process according to claim 10, wherein the structuring element (ES) is an epoxide-type thermosetting resin (ESR).