Method for manufacturing a component for the outfitting of an aircraft passenger cabin
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- SAFRAN SEATS
- Filing Date
- 2024-06-11
- Publication Date
- 2026-04-22
AI Technical Summary
The aerospace industry faces challenges in effectively recycling and reusing carbon fiber scraps, which are often discarded or downcycled due to lack of developed outlets, contributing to material waste and environmental concerns amidst growing regulatory pressures on carbon emissions.
A method for manufacturing aircraft interior components by recycling carbon fiber scraps through producing non-woven layers impregnated with a binder, consolidating them into fiber boards, cutting and assembling these boards, and thermocompressing them into complex shapes, thereby creating lightweight, isotropic components with properties similar to woven structures.
This method reduces material waste, decreases the mass of aircraft components, and enhances environmental sustainability by creating high-performance, recycled materials for aircraft interior fittings, aligning with regulatory standards on carbon emissions.
Smart Images
Figure FR2024050763_19122024_PF_FP_ABST
Abstract
Description
[0001] DESCRIPTION
[0002] TITLE: METHOD FOR MANUFACTURING A COMPONENT FOR FITTING OUT AN AIRCRAFT CABIN
[0003] Technical field of the invention
[0004] The invention relates to the technical field of components for fitting out an aircraft cabin, such components being intended, for example, to equip seats.
[0005] Technical background
[0006] The technical background includes in particular documents DE-A1 -102010042349, EP-A1 -3 643 484, JP-A-S63 125315, US-A1 -2021 / 129453.
[0007] The use of composite materials for the production of aircraft cabin fittings is well known. Such a material generally comprises fibers embedded in a polymer matrix. For example, it is known to use glass fibers, carbon fibers, etc. Other materials are also known for the production of such components, such as aluminum or plastic.
[0008] Carbon fiber consumption has increased significantly over the past ten years. Production has adapted to meet growing demand.
[0009] Mainly used in composite structures, carbon fibers are widely used in the production of woven composite parts in the aeronautics field, particularly woven composite blades for turbojet engines. During their manufacture, the layers of warp and weft yarns are released as a preform of the composite part is created, in order to achieve the different desired thicknesses. When the preform is released from the loom, a cutting operation is carried out. The cut carbon yarns then become scraps from the weaving process.
[0010] Carbon fiber scraps therefore represent a significant potential volume across all production plants. Furthermore, carbon fiber scraps still have intact mechanical performance, as they have not been stressed. They can therefore be reused to manufacture new composite parts.
[0011] However, until recently, carbon fiber scraps were hardly ever recycled. Although carbon fiber scrap processing channels have been developed, they are saturated with demand, particularly from the automotive industry.
[0012] Carbon fiber scraps are therefore not highly valued and outlets for reusing such fibers are still underdeveloped. They are mostly pyrolyzed and then ground into powder, which constitutes fillers for primers, paints or thermoplastic materials.
[0013] Climate change is a major concern for many legislative and regulatory bodies around the world. Indeed, various restrictions on carbon emissions have been, are being, or will be adopted by various states.
[0014] In particular, an ambitious standard applies to both new aircraft types and those already in operation, requiring the implementation of technological solutions to ensure their compliance with current regulations. Civil aviation has been mobilizing for several years now to contribute to the fight against climate change.
[0015] Technological research efforts have already made it possible to significantly improve the environmental performance of aircraft.
[0016] The Applicant takes into consideration the impact factors in all phases of design and development to obtain less energy-intensive, more environmentally friendly aeronautical components and products whose integration and use in civil aviation have moderate environmental consequences with the aim of improving the energy efficiency of aircraft.
[0017] The research and development work supported focuses in particular on lightening the devices, particularly through the materials used and lightened on-board equipment.
[0018] It was therefore considered to recover carbon fiber scraps in order to set up a new sector. In this regard, research and development efforts have made it possible to develop a semi-finished recycling product based on carbon fiber scraps and a process for manufacturing such a product. The product comes in the form of a roll of a strip or a non-woven layer containing carbon fiber scraps and a binder ensuring the cohesion of the fibers between them and the strength of the strip.
[0019] However, to date, no measures aimed at exploiting such a product have been undertaken. The invention therefore aims to provide a method for manufacturing a component for fitting out an aircraft cabin, by recycling carbon fiber scraps.
[0020] To this end, the invention is the result of technological research aimed at significantly improving aircraft performance and, in this sense, contributes to reducing the environmental impact of aircraft.
[0021] Summary of the invention
[0022] For this, the invention provides a method for manufacturing a component, in particular for fitting out an aircraft cabin, comprising at least: a) a production step, during which at least one non-woven layer comprising offcuts of fibers, in particular carbon fibers, impregnated with at least one binder, in particular thermoplastic, such as a thermoplastic matrix, which ensures cohesion of the non-woven layer, is produced; b) a consolidation step, during which the non-woven layer is consolidated, so as to obtain at least one fiber plate, in particular at least one laminated fiber plate; c) a cutting step, during which the plate is cut, and optionally, a superposition step, during which several cut fiber plates are superimposed and assembled together, so as to form a stack, in particular by welding them at several points by ultrasound;and d) a compression step, during which the fiber plate or stack is thermocompressed in a mold, so as to produce a component having a non-planar shape.;
[0023] The invention thus proposes to recover fiber scraps, such as carbon fibers, and thus to recycle them. The invention therefore makes it possible to produce development components from recycled material, which is particularly advantageous from an environmental and economic point of view.
[0024] The recycling of noble aeronautical materials, such as carbon fibers, makes it possible to have an isotropic or quasi-isotropic non-woven structure, particularly in the plane, with properties similar to those produced from woven structures, for example glass fibers, while significantly reducing the mass of the product.
[0025] In this description, the term "furnishing component" should be understood as being a secondary structural component, in particular used to equip a seat, a piece of furniture, a storage chest and / or a trim panel for example. Such a component may have one or more functions chosen from an aesthetic finish, a fixing, etc.
[0026] Furthermore, in the present description, the term "non-woven layer" should be understood as being a layer composed of fibers which are not woven together and which have a random orientation in the non-woven layer. The fibers of the non-woven layer are bound together by at least one binder, a binding material and / or a matrix, in particular a thermoplastic matrix, which ensures a certain cohesion of the non-woven layer.
[0027] The random orientation of the fibers is particularly advantageous because it allows the layer to have the same properties in all directions (isotropic or quasi-isotropic).
[0028] The purpose of consolidation is to stiffen the non-woven layer and thus transform it into a relatively rigid plate. Consolidation can be a heat treatment, possibly combined with a compression treatment.
[0029] In such a case, the heat treatment may be carried out at a temperature greater than or equal to the glass transition or melting temperature of the binder, the binder material and / or the matrix.
[0030] Thermocompression is a combination of heat treatment and compression treatment, which can, for example, be carried out in a press.
[0031] The present invention may include other features, described in the following, which may be considered independently or in combination with each other:
[0032] - the or each fiber plate is cut flat in step c) according to shapes corresponding to a development of the component;
[0033] - the fiber plates are assembled by ultrasonic welding in step c), in particular at several points, so as to form a stack of variable thickness and / or in development of the component; - the fiber plate and / or the stack is heated, in particular by infrared or ceramic convection;
[0034] - the fiber plate and / or the stack is heated to a temperature greater than or equal to the glass transition or melting temperature of the binder, the binder material and / or the matrix, in particular the thermoplastic matrix;
[0035] - the stack is heated, stamped and consolidated in the mold which is regulated at a temperature lower than the solidification temperature of the binder, the binding material and / or the matrix;
[0036] - the mold is configured to form at least one variable thickness, a rib, a groove and / or a hole;
[0037] - the mold is regulated at a temperature, in particular at a temperature lower than a solidification temperature of the binder;
[0038] - an insert intended to be fixed to the component is previously positioned in the mold before the compression step d);
[0039] - the binder is poly(phenylene sulfide) (PPS), polyetherimides (PEI), polyetheretherketone (PEEK), polycarbonate (PC), polyethersulfone (PESU) and / or polyphenylsulfone (PPSU);
[0040] - the compression step d) comprises and / or is followed by overmolding of the component;
[0041] - the cut and superimposed fiber plates are assembled by welding, in particular ultrasonic welding, in particular by point welding, to each other at the superposition stage, so that the stack is in one piece, in particular making it easier to handle the stack before thermocompression;
[0042] - said fiber falls have a random orientation; and / or
[0043] - the component is intended to equip an aircraft seat or is a component of such a seat.
[0044] The present invention also relates to a component, in particular for fitting out an aircraft cabin, in particular for a seat of an aircraft cabin, manufactured by a manufacturing method as described above.
[0045] Furthermore, the manufacturing method according to the invention, which is particularly advantageous for the purpose of reducing the environmental impact of aircraft, relates to a component for fitting out an aircraft cabin, such as a seat element, in particular a shell, a seat, a backrest, an armrest and / or a tray table, obtained by a manufacturing method as described above. The component is preferably a seat component of an aircraft cabin.
[0046] Brief description of the figures
[0047] The present invention will be better understood and other objects, characteristics and advantages of the invention will appear more clearly on reading the following description, comprising examples of embodiments of components for the arrangement presented as non-limiting examples which may serve to complete the understanding of the present invention and the description of its embodiment and, where appropriate, contribute to its definition. This detailed description is made with reference to the appended figures, in which:
[0048] [Fig. 1] Figure 1 is a schematic view of a pile of carbon fiber scraps; [Fig. 2] Figure 2 is a schematic view of a non-woven layer of carbon fiber scraps;
[0049] [Fig.3] Figure 3 are schematic views illustrating steps of a manufacturing method according to the invention; and
[0050] [Fig.4] Figure 4 is a schematic perspective view of a component for fitting out the passenger compartment of an aircraft, manufactured by a manufacturing method according to the invention.
[0051] Detailed description of the invention
[0052] Figure 1 is a schematic view of a cluster of carbon fiber scraps 10.
[0053] Carbon fiber scraps have a length less than or equal to 100mm and, in general, between 10 and 50mm.
[0054] Rather than discarding carbon fiber scraps, the invention proposes to recycle them by producing components for fitting out an aircraft cabin. A component 12 of this type is illustrated in Figure 4. Component 12 is; for example; intended to equip an aircraft seat.
[0055] Figure 2 is a schematic view of a non-woven layer of carbon fiber scraps.
[0056] According to the invention, the component 12 is made from scraps of fibers, in particular carbon fibers, in the form of a layer or a non-woven strip 14, as illustrated in Figure 2.
[0057] The manufacturing method according to the invention comprises at least: a) a production step, during which at least one non-woven layer 14 is produced, the non-woven layer 14 comprising fiber scraps 10, in particular carbon fiber scraps, in particular impregnated with a binder, or a binder material, for example thermoplastic, which ensures cohesion of the non-woven layer 14; b) a consolidation step, during which the non-woven layer 14 is consolidated, so as to obtain at least one fiber plate 18; c) a cutting step, during which the fiber plate 18 is cut and, optionally, a superposition step, during which several cut fiber plates 18 are superimposed and assembled together, so as to form a stack 20;and d) a compression step, during which the fiber plate 18 or the stack 20 is thermocompressed in a mold 16, so as to produce the component 12, having in particular a non-planar shape.;
[0058] In the present description, the term “binder” must be understood as being an element making it possible to ensure cohesion of the non-woven layer 14, such as a binder material and / or a matrix.
[0059] In particular, the cut and superimposed fiber plates 18 are welded to each other in the superposition step, so that the stack 20 is in one piece. This makes it easier to handle the stack 20 with a view to carrying out the compression step d).
[0060] In particular, the cut and superimposed fiber plates 18 are assembled by ultrasonic welding, for example at several points, so as to form a stack of variable thickness and in development of the component 12.
[0061] The step of carrying out the manufacturing method, during which the non-woven layer 14 is produced, may comprise at least: i) a collection step, during which fiber scraps 10, in particular carbon fiber scraps, are recovered; ii) a disentangling step, during which the fibers 10, in particular the carbon fibers, are disentangled and may be mixed with a binder or a binder material; iii) a dispersion step, during which a flow of dry air is used to disperse the fibers 10; iv) a manufacturing step, during which a fiber mat is produced, the fiber mat comprising the fibers 10, air and the binder or the binder material;and v) a calendering step, during which the fiber mat is hot calendered to a temperature greater than or equal to the glass transition temperature of the binder, so as to produce a semi-finished recycling product in the form of a roll of non-woven strip or layer 14.;
[0062] Advantageously, in the collection step i), the fiber scraps 10, in particular carbon fibers, result from the cutting of blanks of parts made of composite materials in the aeronautical field, such blanks being in particular obtained by three-dimensional weaving of carbon fibers using a loom as mentioned above.
[0063] The disentangling sub-step ii) consists of disentangling the fibers 10 and, optionally, mixing them with a binder, or a binding material, in particular at low temperature. The binder may be in the form of particles and / or fibers, for example of a resin-based thermoplastic type, such as polyethylene (PE), polypropylene (PP) or in a PE-PP copolymer.
[0064] The disentangling sub-step ii) may further comprise a mixture of the fibers 10, in particular carbon fibers, with thermoplastic fibers, such as polyetherimides (PEI), poly(phenylene sulfide) (PPS) or polycarbonate (PC).
[0065] Thermoplastic fibers preferably have a glass transition temperature higher than that of the binder.
[0066] The calendering sub-step iv) is carried out at the glass transition temperature of the binder and is intended not to soften the thermoplastic fibers intended to be softened during subsequent processing.
[0067] In the presence of thermoplastic fibers, the semi-finished product can be used to manufacture a finished product after further processing, in particular heating to the glass transition temperature of the thermoplastic fibers, such as hot molding of the non-woven web.
[0068] The dispersion step ill) and the production step iv) of the manufacturing process make it possible, using a flow of dry air, to disperse the fibers 10 and to produce a fiber mat comprising the fibers 10, air and the binder or binding material.
[0069] The calendering step v) then makes it possible to produce the semi-finished recycling product in the form of a roll of non-woven strip 14. The non-woven layer 14 preferably has a thickness of between 0.1 mm and 0.6 mm, and preferably of between 0.2 mm and 0.4 mm.
[0070] The non-woven layer 14 may be associated with a binder or a binding material, in particular a thermoplastic or a thermoset. The thermoplastic binder may, for example, be poly(phenylene sulfide) (PPS), polyetherimides (PEI), polyetheretherketone (PEEK), polycarbonate (PC), polyethersulfone (PESU) and / or polyphenylsulfone (PPSU).
[0071] Thermoplastic fibers preferably have a glass transition or melting temperature higher than that of the binder.
[0072] The non-woven layer 14 may have a surface density of between 100g / m 2 and 1000g / m 2 , especially between 200g / m 2 and 600g / m2 .
[0073] Figure 3 includes schematic views illustrating several steps of the manufacturing method according to the invention.
[0074] More particularly, Figure 3 illustrates very schematically the various stages of the manufacturing process from production stage a) to compression stage d).
[0075] Images 3a and 3b show step a) of the manufacturing process.
[0076] Image 3b further shows the consolidation step b), during which the fiber plate 18 is consolidated and obtained from the fiber scraps 10. The consolidation preferably takes place by heating the non-woven layer 14 beyond the glass transition or melting temperature of the binder.
[0077] The mass fiber content of the fiber plate 18 is between 40% and 60%, in particular between 45% and 55%, in particular substantially 50%.
[0078] Image 3c illustrates the cutting step c), in particular a cutting of the fiber plate 18 and, possibly, a superposition of several fiber plates 18 or several pieces of fiber plates cut to form the stack 20 by assembling them together.
[0079] The 3d image illustrates an intermediate step of heating the fiber plate 18 or the stack 20, in order to soften the fiber plate 18 or the stack 20. Such heating can be carried out at a temperature greater than or equal to the glass or melting temperature of the binder. The fiber plate 18 or the stack 20 can be heated by conduction by the mold 16. Alternatively, the fiber plate 18 or the stack 20 can be heated by infrared or ceramic convection. The 3e image illustrates the compression step d) consisting of an introduction of the fiber plate 18 or the stack 20 into the mold 16, in order to undergo thermocompression therein.
[0080] Conventionally, the mold 16 comprises two parts, respectively an upper part 16a and a lower part 16b, between which the fiber plate 18 or the stack 20 is arranged. The upper part 16a and the lower part 16b comprise impressions for the formation of the component 12. The heated and flexible fiber plate 18 or the stack 20 is stamped when the mold 16 is closed. As a result, the fiber plate 18 or the stack 20 is reconsolidated into a shaped part.
[0081] The mold 16 can be temperature-regulated, in particular at a temperature below a solidification temperature of the polymer matrices.
[0082] Figure 4 is a schematic perspective view of the component 12 for an aircraft cabin layout, manufactured by the manufacturing method according to the invention.
[0083] More particularly, as seen in Figure 4, component 12 has a non-planar shape, including a complex three-dimensional shape.
[0084] The mold 16 is preferably configured to form at least one variable thickness, rib, groove, and / or hole in the component:
[0085] In a particular case, an insert may be intended to be fixed to the component 12. For this purpose, the insert is previously positioned in the mold 16, before the consolidation step b).
[0086] Image 3f illustrates a stamping or embossing step.
[0087] Optionally, the manufacturing method according to the invention may include an overmolding step, during which the component 12 is, at least in part, overmolded. The overmolding step may be carried out with an injection polymer of the same nature as the polymer used as a binder or binding material for the fiber plate 18 or the stack 20.
[0088] The overmolding step can be carried out during the compression step d) or after the compression step d).
[0089] The present invention provides several advantages including:
[0090] - a reduction in material losses (particularly carbon fibers) during the composite manufacturing cycle in the aeronautics sector, - recycling of this material for the interior fittings of an aircraft, such as airplane seats,
[0091] - a reduction in the mass of the interior design components thus obtained and, consequently, a reduction in the carbon footprint linked to air transport, - etc.
Claims
CLAIMS 1. Method for manufacturing a component (12), in particular for fitting out an aircraft cabin, in particular for a seat of an aircraft cabin, comprising at least: a) a production step, during which at least one non-woven layer (14) comprising fiber scraps (10) impregnated with at least one binder is produced; b) a consolidation step, during which the non-woven layer (14) is consolidated, so as to obtain at least one fiber plate (18); c) a cutting step, during which the plate (18) is cut; and optionally, a superposition step, during which several cut fiber plates (18) are superimposed and assembled together, so as to form a stack (20); and d) a compression step, during which the fiber plate (18) or the stack (20) is thermocompressed in a mold (16), so as to produce a component (12) having a non-planar shape.
2. Manufacturing method according to claim 1, in which the fiber plate (18) or the stack (20) is heated by infrared or ceramic convection.
3. Manufacturing method according to claim 1 or 2, in which the fiber plate (18) and / or the stack (20) is heated to a temperature greater than or equal to the glass transition or melting temperature of the binder.
4. Manufacturing method according to any one of the preceding claims, wherein the mold (16) is configured to form at least one variable thickness, a rib, a groove and / or a hole.
5. Manufacturing method according to any one of the preceding claims, wherein the mold (16) is regulated at a temperature, in particular at a temperature below a solidification temperature of the binder.
6. Manufacturing method according to any one of the preceding claims, in which an insert intended to be fixed to the component (14) is previously positioned in the mold (16) before the compression step d).
7. A manufacturing method according to any one of the preceding claims, wherein the binder is poly(phenylene sulfide) (PPS), polyetherimides (PEI), polyetheretherketone (PEEK), polycarbonate (PC), polyethersulfone (PESU) and / or polyphenylsulfone (PPSU) 8. Manufacturing method according to any one of the preceding claims, in which the compression step d) comprises and / or is followed by a step of overmolding the component (12).
9. Manufacturing method according to any one of the preceding claims, in which the cut and superimposed fiber plates (18) are assembled by welding, in particular ultrasonic welding, in particular by point welding, to each other in the superposition step, so that the stack (20) is in one piece.
10. Manufacturing method according to any one of the preceding claims, wherein said fiber scraps (10) have a random orientation.
11. A manufacturing method according to any one of the preceding claims, wherein the component is a seat component of an aircraft cabin.
12. Manufacturing method according to any one of the preceding claims, in which the or each fiber plate is cut flat in step c) according to shapes corresponding to a development of the component.
13. Manufacturing method according to any one of the preceding claims, in which the fiber plates are assembled by ultrasonic welding in step c), in particular at several points, so as to form a stack of variable thickness and / or in development of the component.
14. Manufacturing method according to any one of the preceding claims, in which the stack is heated, stamped and consolidated in the mold which is regulated at a temperature lower than the solidification temperature of the binder.
15. Component (12), in particular for fitting out an aircraft cabin, characterized in that the component (12) is obtained by a manufacturing method according to any one of the preceding claims.
16. Component (12) according to the preceding claim, wherein the component is a seat component of an aircraft cabin.