Method for producing a separation device made of composite material, separation device obtained thereby and aircraft components comprising such a separation device

Description

[0001] The present invention relates to a method for manufacturing a partition device made of composite material intended to withstand various stresses while being lightened, as well as the partition device obtained, and aircraft constituent elements manufactured using such a partition device.

[0002] Such a partition system can be used in a wide variety of fields, including, but not limited to, construction and aeronautics. While in construction the criterion of lightness is useful during construction, in aeronautics it is primarily used.

[0003] A partition device according to the invention can thus, in the aeronautical field, find outlets for the construction of aircraft or helicopter cells, as well as floors, doors, hatches and even seat structures for these same aircraft and helicopters.

[0004] The following description relates essentially to aeronautics, while knowing that the partition device according to the invention can be applied to other fields. In addition, this description is more particularly devoted to a partition device for the production of an aircraft door, knowing that other parts of an aircraft can be produced from such a partition device, namely, without limitation, parts of fuselage cells, but also floor elements.

[0005] In the field of aeronautics, the partitions constituting the cells of an aircraft fuselage traditionally consist of a skin supported by longitudinal stringers, themselves fixed to longitudinally distributed frames. Such an architecture requires numerous assembly points.

[0006] When we want to make such a structure in composite material, it is necessary either to materialize all the assembly points, which is delicate and complex, or to implement it in a very complex mold to create a monolithic structure, a method currently used in the production of composite aircraft doors.

[0007] Another composite solution consists of making sandwich panels composed of two distant skins separated by a core often made of foam or honeycomb. The distance between the two skins, combined with the transmissibility of force flows through the core, allows the structure to withstand mechanical bending.

[0008] However, this solution is not suitable for complex shapes or those requiring the presence of volumes between the two structural skins to place mechanisms there, for example in the case of aircraft doors.

[0009] Thus, we know from document US 6,047,925 a hatch or a door if it is small, made in the form of a composite sandwich. We can see in this document that it is very difficult to report the fixing elements necessary for holding the door on the structure of the aircraft, and also that the complex mechanisms necessary for the operation of the door cannot be integrated inside the door.

[0010] Document US 6,554,226 describes a door made from a molded composite material, exactly reproducing the characteristics of a metal door, according to the concept of "black metal", which leads to a result of low technical and economic efficiency.

[0011] Documents EP 2 415 662 and WO 2007 / 062641 also describe aircraft doors, and show the complexity of making a skin cooperate with a cross member of a supporting structure. Document WO2012 / 156525A1 discloses a method of manufacturing a partition device made of composite material by assembling reinforcements on a panel.

[0012] The aim of the present invention is to propose a method for manufacturing a partition device made of composite material intended to withstand various stresses while being lightened, in order to provide solutions to the drawbacks set out above.

[0013] The method of manufacturing a partition device made of composite material according to the invention is characterized in that it consists of successively carrying out the following operations: obtaining, by a shaping process suitable for the composite material used, a first panel having on the one hand a shape specific to its intended purpose, possibly curved, and thus defining a so-called inner face and a so-called outer face; and comprising on the other hand longitudinal deformations of omega profile, to form ribs projecting from the so-called inner face, peripherally cutting this first panel to the necessary shape, obtaining, by a shaping process suitable for the composite material used, a second panel having on the one hand a shape identical to that of said first panel, and thus defining a so-called inner face and a so-called outer face which are the opposite of those of said first panel;and further comprising longitudinal deformations of omega profile of depth equal or not to those of the first panel, to form ribs projecting from the so-called inner face, and in an orientation different from that of the deformations of said first panel, peripherally cutting this second panel to the necessary shape, assembling the two panels inner face of one against the inner face of the other, so that they touch by the crossing of the ribs, joining the two panels at the level of the contact zones of said ribs. ;

[0014] According to an additional characteristic of the method according to the invention, the first and second panels come from the shaping by hot deformation under pressure of thermoformable composite material blanks.

[0015] According to a variant of the method according to the invention, the first and second panels come from the molding of a thermosetting composite material.

[0016] According to an additional characteristic of the method according to the invention, the ribs of one panel cross those of the other panel at right angles.

[0017] According to another additional characteristic of the method according to the invention, the first and second panels are made of thermoplastic composite material, and they are joined by welding.

[0018] According to another additional characteristic of the method according to the invention, the two panels are joined by gluing.

[0019] According to another additional characteristic of the method according to the invention, the two panels are joined together by means of additional fixing elements.

[0020] It should be noted that the use of additional fixing elements can be superimposed on the securing by welding or gluing.

[0021] According to another additional characteristic of the method according to the invention, the additional fixing elements consist of pairs of fishplates, a first fishplate comprising a face shaped with the bottom of a deformation made in one panel and into which deformation it is introduced, and a second fishplate comprising a face shaped with the bottom of a deformation made in the other panel and into which deformation it is introduced, and in that they are fixedly connected through connecting means which pass through said deformation bottoms at the level of the contact zones of the ribs.

[0022] According to another additional characteristic of the method according to the invention, the additional fixing elements consist of connection fittings, arranged at the end of the assembly of two panels, and comprising on the one hand an element shaped to cooperate with the end of a deformation of a panel, and on the other hand an element to receive the other panel as a support.

[0023] According to another additional characteristic of the method according to the invention, the connection fittings arranged at the end of the assembly of two panels, comprise means of cooperation with other panels.

[0024] The partition obtained by the method according to the invention has properties of resistance to external stresses due to the fact that this judicious combination makes it possible to offer resistance to bending in any direction.

[0025] In the non-limiting case of application to an aircraft door, such a partition is a break with the usual forms, it is adapted to a composite design which greatly minimizes the production cost by: the significant reduction in the number of parts constituting the door structure, the ease of production of the two skins, the ease of inspection of the material health of the two skins, the ease of joining the two skins

[0026] According to another additional characteristic of the method according to the invention, the hollow shapes of at least one panel are filled, so as to create a continuous surface.

[0027] According to another additional characteristic of the method according to the invention, the hollow shapes of at least one panel are filled, and the face thus filled is covered with a non-structural skin.

[0028] According to another additional characteristic of the method according to the invention, mechanisms and / or a sound and / or thermal insulating material are inserted into the volumes created between the two panels.

[0029] According to another additional characteristic of the method according to the invention, during the peripheral cutting operation of one and / or the other of the two panels, the ribs are cut out to leave an end part emerging from the contour, which is machined to serve as a connecting element.

[0030] According to another additional characteristic of the method according to the invention, during the shaping of the panel(s), one and / or the other end of one or more omega profile deformations is closed.

[0031] The bending strength of the cut ends of the ribs allows for fixing without the need for hardware. The fact that the ends of the ribs are closed increases the bending strength.

[0032] The present invention also relates to a partition device produced according to the method described above, as well as aircraft constituent elements such as a cell element, a door, a floor.

[0033] The advantages and characteristics of the method for manufacturing a partition device made of composite material according to the invention will emerge more clearly from the description which follows and which relates to the attached drawing, which represents a non-limiting embodiment thereof.

[0034] In the attached drawing: THE figures 1a, 1b et 1c , represent schematic perspective views of successive stages of the manufacturing process of a partition device made of composite material, the figure 2 represents a perspective view with partial cutaway, of an aircraft door consisting of a partition device according to the invention. figures 3a et 3b , represent schematic perspective views of successive stages of the manufacturing process of another partition device made of composite material, the figure 4 represents a longitudinal sectional view of the partition device of figure 2b, the figure 5 represents a cross-sectional view of the partition device of Figure 2b, the figure 6 represents a schematic perspective and exploded view of elements used in the manufacturing process of a partition device made of composite material, the figure 7 represents a sectional view of a part of a partition device according to the invention, the figure 8 represents a partial perspective view of a partition device according to the invention, intended for the production of a floor, the figure 9 represents a perspective view of a fitting used for the construction of the floor of the figure 8 , there figure 10 represents a perspective view of part of an aircraft cell, including a floor reproduced in figure 8 . there figure 11 represents a perspective view of a seat structure, produced with a partition device according to the invention.

[0035] In reference to the figures 1a, 1b et 1c , it can be seen that the method of manufacturing a partition device 1 made of composite material according to the invention, visible on the figure 1c , begins with the manufacture of two panels 2 and 3.

[0036] It will be noted that the partition device 1 which will be described consists, non-limitingly, of a constituent element of an aircraft fuselage, which may be a part of the cell of this fuselage or a door, and for this purpose this partition device 1 has a certain curvature, its convex face 10 corresponding to the external side of the fuselage, while its concave face 11 corresponds to the internal face of the fuselage.

[0037] Of course, in the case of another constituent part of an aircraft such as a floor element for example, the partition device is flat.

[0038] Furthermore, by way of non-limiting example, the description below relates to the use of a thermoformable composite material. It will therefore be noted that in the case of using a thermosetting material, panels 2 and 3 would be obtained by a polymerization molding operation.

[0039] Each of the panels 2 and 3 comes from the hot deformation under pressure of a thermoformable composite blank, respectively 20 and 30, in this case rectangular in shape.

[0040] The blank 20 is deformed to, on the one hand, give it a curved shape, in this case it is bent lengthwise, and on the other hand to create omega-type deformations, creating longitudinal ribs 21 which are consequently also curved.

[0041] The deformations are created in the convex face 22 called the exterior, so that the ribs 21 protrude from the concave face 23 called the interior.

[0042] The blank 30 is deformed to, on the one hand, give it the same curved shape, namely that it is also curved in the length direction, and on the other hand to create omega-type deformations, creating transverse ribs 31 which are consequently rectilinear.

[0043] The deformations are created in the concave face 32 called the exterior, so that the ribs 31 protrude from the convex face 33 called the interior.

[0044] The panels 2 and 3 are intended to be assembled together, inner faces 23 and 33 against each other, and more particularly by means of the ribs 21 and 31, and their parts respectively 24 and 34 which constitute the bottoms of the deformations.

[0045] On the figure 1b , the contact zones Z with the ribs 21 when the two panels 2 and 3 are brought together are shown on the ribs 31, to form the partition device 1 of the figure 1c .

[0046] It will be noted that in this particular embodiment the ribs 21 are parallel, as are the ribs 31, and that consequently they cross at right angles when the panels 2 and 3 are brought together. It could be otherwise, the ribs of the same panel could be parallel and cross the ribs of the other panel non-perpendicularly, and these ribs of the same panel could not be parallel, many combinations are of course possible.

[0047] It can also be noted that the deformations made in one panel may be different from those made in the other panel, particularly in terms of depth so that the ribs of one are higher than those of the other.

[0048] It should also be noted that according to the process, a peripheral cut is made after the deformation operation, unless the blank, 20 or 30, is of dimensions conforming to the shape of the panel, respectively 2 and 3.

[0049] The partition device 1 obtained can allow the manufacture of an aircraft door P, such as that shown in the figure 2 .

[0050] Now referring to the figures 3a et 3b , we can see a partition device 4 produced according to the method, of curved shape and comprising a convex face 40 and a concave face 41, coming from the assembly of two panels 5 and 6.

[0051] Panel 5 comes from the deformation of a rectangular blank 50 curved in the length direction, and comprising omega-type deformations, creating curved longitudinal ribs 51, while panel 6 comes from the deformation of a rectangular blank 60 also curved in the length direction, and comprising omega-type deformations, creating rectilinear transverse ribs 61.

[0052] The deformations of the blank 50 are created in its convex face 52 called the outer face, so that the ribs 51 protrude from its concave face 53 called the inner face. Similarly, the deformations of the blank 60 are created in its concave face 62 called the outer face, so that the ribs 61 protrude from the convex face 63 called the inner face.

[0053] It will further be noted that the ribs 51 do not extend over the entire length of the blank 50 so that they are closed at their ends 54.

[0054] The ribs 61 extend beyond the lateral edges 64 of the blank 60 and are closed at their ends 65, which is obtained by creating partial ribs 61 as the ribs 51 are created, then by peripheral cutting, in accordance with the method according to the invention.

[0055] The configuration of the end parts of the ribs 61, namely closed at their ends 65, gives these parts which extend beyond the lateral edges 64, a resistance to bending which allows their use for fixing purposes, and makes it possible to dispense with the use of connecting fittings.

[0056] The ribs 51 and 61 may be intended to house additional elements such as reinforcements or fixing means, the closed ends 54 and 65 making it possible to conceal these additional elements if necessary.

[0057] THE figures 4 et 5 show the assembly of the two panels 5 and 6, by bringing the ribs 51 into contact with the ribs 61, and more precisely the parts 55 and 66 which constitute the bottoms of the deformations.

[0058] The joining of the panels 2 and 3, and 5 and 6, together can be achieved in various ways, for example, but not limited to, by gluing, by welding, by mechanical bonding, the welding bond requiring the composite to be thermoformable. It is also possible for the gluing or welding to be combined with a mechanical bond.

[0059] The mechanical connection can for example consist of riveting, but preferably fishplates are used, as shown in the figure 5 , and as seen on the figure 6 .

[0060] There figure 6 shows a mechanical connection 7 comprising two splints 70 and 71 of identical shapes, each intended to be housed in an omega-type deformation, against the bottom of the deformation, and for this purpose, they each comprise a flat part respectively 72 and 73, capable of coming into close contact with a bottom. The splints 70 and 71 are consequently intended to cross.

[0061] The fishplates 70 and 71 are pierced with holes, respectively 74 and 75, with axes perpendicular to the flat faces respectively 72 and 73, in this case four, distributed so that when the fishplates 70 and 71 are positioned perpendicular to each other, each hole 74 is coaxial with a hole 75. The holes of a fishplate, in this case the holes 75 of the fishplate 71, are tapped, while the holes 74 of the fishplate 70 are chamfered to accommodate screw heads not shown.

[0062] Advantageously, the face, respectively 76 and 77, opposite the flat face, respectively 72 and 73, is curved, allowing a lightening of the fishplate, respectively 70 and 71.

[0063] On the other hand, the lateral faces 78 are not perpendicular to the flat face, respectively 72 and 73, but inclined, flaring out from the flat face, respectively 72 and 73 towards the curved face, respectively 76 and 77, so as to be able to closely match the internal shape of the deformations.

[0064] Of course, the splints could have simpler shapes, for example being made of parallelepiped bars.

[0065] In reference to the figure 7 , we can see a part of the partition device 4, and in particular an assembly zone of the panels 5 and 6 by means of a mechanical connection 7.

[0066] The panels 5 and 6 are joined, the ribs 51 and 61 cross, the bottoms 55 and 66 of the deformations are in contact, possibly glued or welded, while a fishplate 70 is arranged against the bottom 66 and a fishplate 71 is arranged against the bottom 55, and these bottoms 55 and 66 are, at the contact zone Z, pierced with holes 42 in line with the holes 74 and 75, to allow the passage of screws 79, in order to clamp the two panels 5 and 6.

[0067] In addition to the manufacture of the partition device 4, the interior of the rib 51 is filled with a filling material 43 such as foam for example, while a non-structural skin 44 covers the entire exterior face 53 of the panel 5.

[0068] Additionally, the interior volume of the partition device 4, i.e. the volume between the ribs 51 and 61, can be filled with a sound and / or thermal insulating material.

[0069] It should also be noted that it may be necessary, for the construction of large walls for example, to butt partition devices; in this case, fishplates are used to connect the panels of different partition devices together.

[0070] Now referring to the figure 8 , we can see a partition device 8, of generally flat shape, and more particularly intended to be positioned horizontally, for the production of a floor, in particular of an aircraft.

[0071] The partition device 8 is produced by assembling two panels, upper 80 and lower 81, each provided with parallel ribs, respectively 82 and 83, which cross during assembly in zones Z.

[0072] The assembly is completed by additional fixing elements, such as connection fittings 84, one of which is shown in the figure 9 , which comprises an internal face 85 shaped to fit at the end of the partition device 8, that is to say having on the one hand a projecting element 86 engaging in the end of the rib which opens at the end, in this case a rib 83 of the panel 81, and on the other hand a support element 87 which comes into contact with the internal face of the other panel, in this case 80.

[0073] Such fittings 84, which can be made of metal or composite material, make it possible to guarantee the spacing of the two panels 80 and 81, at the end of the partition device 8, when the zones Z are far from this end.

[0074] The connection fittings 84 comprise, externally with respect to the internal face 85, an external face 88 having a particular profile, projecting with respect to the end of the partition device 8.

[0075] In reference to the figure 10 , a partition device 8 can be seen constituting a floor for an aircraft cell. The cell consists of a partition device 1, which differs from the partition device 1 of the figure 1 , in that the ribs 31 of the convex internal face 11 are curved, and therefore in parallel vertical planes.

[0076] Thus, as can be seen, the connection fittings 84 which equip the partition device 8 are each engaged in a rib 31 by their external face 88, which has for this purpose a male imprint 89 of a shape complementary to this rib 31.

[0077] The fittings 84 allow the partition device 8 to be secured to the partition device 1, i.e. the floor to the wall of the cell.

[0078] Now referring to the figure 11, we can see another object obtained by the method according to the invention. It is a seat structure 9, consisting of the assembly of two panels 90 and 91 provided with ribs, respectively 92 and 93, and folded to form a seat 94 and a backrest 95.

[0079] Of course, other objects can be produced from a partition device obtained by the method according to the invention.

Claims

1. Method for producing a composite partition device, characterized in that it consists in carrying out the following operations consecutively: - obtaining, by means of a shaping method suitable for the composite material used in said production, a first panel (2; 5; 80) having a shape suitable for its destination, which is optionally curved, and thus defining a so-called inner face (23; 53) and a so-called outer face (22; 52); and the first panel comprising omega-shaped longitudinal deformations (21; 51; 82), to form ribs projecting from the so-called inner face (23; 53), - peripherally cutting this first panel (2; 5; 80) to the required shape, - obtaining, by means of a shaping method suitable for the composite material used, a second panel (3; 6; 81) having a shape identical to that of said first panel (2; 5; 80), and thus defining a so-called inner face (33; 63) and a so-called outer face (32; 62) opposite to those of said first panel (2; 5; 80); and the second panel comprising omega-shaped longitudinal deformations (31; 61; 83) of equal or unequal depth to those of the first panel (2; 5; 80), to form ribs projecting from the so-called inner face (33; 63) in a different direction to that of the deformations (21; 51; 82) of said first panel (2; 5; 80), - peripherally cutting this second panel (3; 6; 81) to the required shape, - assembling the two panels (2, 3; 5, 6; 80, 81) with the inner face of one (23; 53) against the inner face of the other (33; 63), so that they touch at the intersection of the ribs (21, 31; 51, 61; 82, 83), - securing the two panels (2, 3; 5, 6; 80, 81) at the contact zones (Z) of said ribs (21, 31; 51, 61; 82, 83).

2. Method according to claim 1, characterized in that the first panel and the second panel (2, 3; 5, 6; 80, 81) are molded from a thermosetting composite material.

3. Method according to claim 1, characterized in that the first panel and the second panel (2, 3; 5, 6; 80, 81) are shaped by hot press forming of blanks (20, 30; 50, 60) made of thermoformable composite material.

4. Method according to claim 1, characterized in that the ribs (21; 51; 82) of one panel (2; 5; 80) intersect those (31; 61; 83) of the other panel (3; 6; 81) at right angles.

5. Method according to claim 3 or claim 4, characterized in that the first panel and the second panel (2, 3; 5, 6; 80, 81) are made of a thermoplastic composite material and are secured together by welding.

6. Method according to any one of claims 1 to 4, characterized in that the two panels (2, 3; 5, 6; 80, 81) are secured together by bonding.

7. Method according to any one of claims 1 to 6, characterized in that the two panels (2, 3; 5, 6; 80, 81) are secured together by means of fastening attachments (7; 84).

8. Method according to claim 7, characterized in that the fastening attachments (7) consist of pairs of fishplates (70, 71), a first fishplate (70) comprising a face (72) shaped to match the bottom of a deformation (61) made in one panel (6) and into which deformation (61) it is introduced, and a second fishplate (71) comprising a face (73) shaped to match the bottom of a deformation (51) made in the other panel (5) and into which deformation (51) it is introduced, and in that they are fixedly connected through connection means (79) which pass through said deformation bottoms at the contact zones (Z) of the ribs (51, 61).

9. Method according to claim 7, characterized in that the fastening attachments consist of connection fittings (84), arranged at the end of the assembly of two panels (80, 81), and comprising both an element (86) shaped to engage with the end of a deformation (83) of one panel (81), and an element (87) for the other panel (80) to bear against.

10. Method according to claim 9, characterized in that the connection fittings (84) arranged at the end of the assembly of two panels (80, 81) comprise means (89) for engaging with other panels (3).

11. Method according to any one of claims 1 to 10, characterized in that the recessed shapes of at least one panel are filled, so as to create a continuous surface.

12. Method according to claim 11, characterized in that the filled face of the panel is covered with a non-structural skin (44).

13. Method according to any one of claims 1 to 12, characterized in that mechanisms and / or sound and / or heat insulating material (43) are inserted into the volumes created between the two panels.

14. Method according to any one of claims 1 to 13, characterized in that during the peripheral cutting operation of one and / or the other of the two panels, the ribs are cut out to leave one to emerge from the contour an end part, which is machined to serve as a connection element.

15. Method according to claim 14, characterized in that, during shaping of the panel(s), one and / or the other end of one or more omega-shaped deformations are closed.

16. Partition device made of composite material (1; 4; 8), characterized in that it is obtained by the method according to any one of claims 1 to 15.

17. Aircraft component, characterized in that it is obtained from a partition device (1; 4; 8) according to claim 16.