Composite panel

Abstract

The invention relates to a composite panel (1) comprising a core (10), having at least a first principal surface (11a) and a second principal surface (11b), opposite each other, a first skin (30a), applied against at least a portion of the first principal surface (11a) of the core (10), and / or a second skin (30b), applied against at least a portion of the second principal surface (11b) of the core (10), wherein the core comprises at least one reinforcement (12) having at least one bar (13) produced by additive manufacturing and extending in at least one extension direction, and a filler material (20), filling at least one cell (14) of the reinforcement (12) delimited by the bar (13). Figure to be published with the abstract: Fig. 1.

Description

Title of the invention: Composite panel Technical field

[0001] The present disclosure relates to a composite panel, a seat comprising such a composite panel, as well as a method of manufacturing a composite panel.

[0002] Such a composite panel can be used in all areas where lightweight composite panels, also conventionally called “sandwich” panels, are used.

[0003] Such a composite panel is thus particularly useful in the field of air transport for manufacturing any type of lightweight component, integrated in particular into an aircraft cabin, for example an aircraft seat, in particular aircraft seat shells.

[0004] However, such a composite panel can also be used in the field of land transport, in particular to form caravan, mobile home or trailer structures, or in the field of maritime transport, in particular to form boat cabins. Prior art

[0005] The use of sandwich panels is well known in fields requiring structures that are both light and strong. Thus, such sandwich panels are often used in the field of air transport, in particular to form seat shells. Such a sandwich panel comprises a two-dimensional core, made of a low-density material, typically porous or cellular, and two skins, generally thermoplastic or thermosetting, possibly reinforced with fibers, attached to each main face of the core.

[0006] Such a classic “sandwich” panel brings many advantages but nevertheless also has disadvantages.

[0007] Firstly, the very architecture of such "sandwich" panels greatly hinders the freedom of geometry of a final part. In particular, variations in thickness are only possible at the cost of additional machining steps.

[0008] In addition, large baking molds, the size of which is adjusted to that of the sandwich panel, remain necessary to hold the sandwich panel during a baking step.

[0009] Furthermore, fixing inserts and other accessories to the sandwich panel is complex and results in a loss of time and an increase in mass.

[0010] Indeed, the structure of the core not being sufficiently rigid to receive such inserts or accessories, it is necessary to locally inject a material of densi- fication, machining it and gluing the insert into a niche thus machined.

[0011] Similarly, it is generally necessary to inject a densifying material along a peripheral edge of the core, in order to plug pores and / or cells of the core, at least on the surface, in order to stiffen the peripheral edge of the core and to insulate the core against moisture and foreign particles.

[0012] Finally, repairing such a type of “sandwich” panel is also complex and adds even more mass.

[0013] There is therefore a real need for a composite panel, a seat, as well as a method of manufacturing a composite panel, which are free from the drawbacks inherent in the aforementioned known configuration. Statement of the invention

[0014] The present disclosure relates to a composite panel, comprising - a core, having at least a first main surface and a second main surface, opposite each other, - a first skin, applied against at least part of the first main surface of the core, and / or - a second skin, applied against at least part of the second main surface of the core

[0015] More particularly, the core comprises a reinforcement comprising - at least one bar produced by additive manufacturing and extending in at least one direction of extension, in particular so as to delimit at least one cell, and - a filling material, filling at least one cell of the reinforcement delimited by the bar.

[0016] In addition, the bar produced by additive manufacturing can extend in at least two different extension directions. The frame can comprise a plurality of such bars extending in at least two extension directions; these bars can then delimit cells at the discretion of their intersections. The filling material can be a porous or cellular material.

[0017] In such a composite panel, the reinforcement of the core forms a rigid skeleton which, - on the one hand, intrinsically increases the rigidity of the core and therefore of the final composite panel, and - on the other hand, also offers locally rigid portions which can serve as support and / or attachment zones during the manufacture of the composite panel and / or, at the end of manufacture, during accessorization and / or fixing in a usage environment.

[0018] In particular, the reinforcement provides the core with sufficient rigidity to ensure a hold during the consolidation of the composite panel. Thus, the use of shaping tools, such as molds, during consolidation is made superfluous and / or greatly reduced.

[0019] In addition, such a reinforcement makes it possible to locally stiffen certain desired areas of the composite panel, for example an edge, without having to inject a densifying material. Such rigid areas also facilitate the installation of inserts and / or other accessories, without having to resort to injecting a densifying material.

[0020] Furthermore, the use of an additive manufacturing technique for producing the frame offers great freedom of design, in particular great freedom of geometry, for the frame and therefore for the composite panel as a whole. It is thus, for example, easy to produce a frame having curves and / or variations in thickness.

[0021] Once the general geometry has been obtained using the reinforcement, it is then sufficient to fill the cells, quickly and easily, using blocks of filling material, in order to obtain a core having the desired geometry.

[0022] In this regard, a block of filling material is preferably installed in each of the cells of the frame, the filling material being a porous or cellular material.

[0023] The fixing of the blocks of filling material to the frame can be carried out by simple removal, clamping, gluing and / or mechanical fixing, in particular via the use of pins, screws and / or a clamping system.

[0024] Thus, the invention is the result of technological research aimed at very significantly improving the performance of aircraft and, in this sense, contributes to reducing the environmental impact of aircraft.

[0025] In certain embodiments, the first main surface and the second main surface of the core are locally parallel. Such a property is verified, in particular, at any point of the core.

[0026] In some embodiments, the core is essentially two-dimensional. In other words, a thickness of the core is very small compared to the two extension dimensions. However, although two-dimensional, this does not prevent it from being curved in three dimensions and therefore from occupying a three-dimensional volume.

[0027] In some embodiments, the core is curved. In such a case, at least one direction of extension of the core is curvilinear. Thus, the core may be curved in a single direction of curvature or in two different directions of curvature.

[0028] In certain embodiments, the frame is manufactured by additive manufacturing in a single piece. The entire frame is thus obtained in a single step. The frame is thus devoid of an assembly interface.

[0029] In some embodiments, the frame comprises several separate subassemblies manufactured by additive manufacturing and assembled together. Such assembly may in particular be carried out by clamping, screwing and / or gluing. Such an option is particularly useful when the frame is large.

[0030] In certain embodiments, two directions of extension of the bars are orthogonal in the frame of reference, that is to say in the frame of reference of the core. Such a configuration thus makes it possible to increase the mechanical strength of the assembly.

[0031] In certain embodiments, at least one direction of extension of the bars is parallel to a direction of curvature of the core. Such a configuration thus makes it possible to increase the bending strength.

[0032] In certain embodiments, the reinforcement extends along at least 80% of the edge of the core, in particular along at least 90% of the edge of the core, in particular along the entire edge of the core. In particular, all or part of the cells of the reinforcement are thus laterally closed. This makes it possible to stiffen the edge of the panel and to isolate the blocks of filling material from the outside, in particular against humidity and foreign particles. In addition, this makes it possible to produce an edge also obtained by additive manufacturing, in the continuity of the manufacture of at least one of the reinforcements forming a final edge of the composite panel requiring finishing.

[0033] In certain embodiments, the first main surface, respectively the second main surface, of the frame is solid. Such a configuration thus makes it possible to provide rigid support surfaces, in particular facilitating the draping of the skins.

[0034] In some embodiments, at least one peripheral surface of the frame is solid. Such a configuration makes it possible to isolate the interior of the frame from moisture and foreign particles. In particular, this makes the injection of a densifying material unnecessary.

[0035] In some embodiments, at least one portion of the reinforcement is of a thickness greater than a thickness of at least one other portion of the reinforcement. Thus, variations in thickness can be easily created for the composite panel.

[0036] In certain embodiments, at least a portion of the reinforcement has a honeycomb structure. Such a portion of the reinforcement thus comprises at least 20%, preferably at least 50%, more preferably 90%, of void space. Such a configuration thus makes it possible to limit the mass of the reinforcement and therefore of the core.

[0037] In some embodiments, at least a portion of the frame has a solid structure. Such a portion thus benefits from increased rigidity. In addition, it is possible to easily machine such a solid portion, which can be useful for installing inserts and / or other accessories.

[0038] In some embodiments, the frame comprises at least one niche configured to receive an insert. Since such a niche is formed at the time of additive manufacturing, no subsequent machining is necessary.

[0039] In certain embodiments, it is even possible to manufacture the frame, or the relevant subassembly of the frame, around such an insert, thus integrating the insert from the additive manufacturing stage.

[0040] In some embodiments, at least one bar of the frame has at least three distinct branches. Such a configuration makes it possible to obtain more complex final architectures, comprising several branches extending in several directions, each branch forming a composite panel with a core and two skins.

[0041] In some embodiments, the frame may be made of a polymer material.

[0042] In some embodiments, the filler material comprises at least 20% void, preferably at least 50% void, more preferably at least 90% void. Such a configuration thus makes it possible to limit the mass of the filler material.

[0043] In some embodiments, wherein the filler material is a foam and / or a honeycomb structure.

[0044] In certain embodiments, the first skin, respectively the second skin covers at least 90%, preferably at least 95%, more preferably at least 99%, of the first main surface, respectively of the second main surface, of the core.

[0045] In some embodiments, at least one skin comprises a thermoplastic or thermoset-based matrix.

[0046] In some embodiments, at least one skin is reinforced with fibers, preferably carbon, glass and / or aramid fibers. Such fibers may be short and / or long according to the usual definitions in the field.

[0047] In some embodiments, at least one skin is - a plate and / or - a sheet, preferably a pre-impregnated sheet.

[0048] In some embodiments, a film of glue is present between the first skin and the core and / or between the second skin and the core.

[0049] The present disclosure also relates to a seat, in particular an aircraft seat, comprising at least one composite panel according to any one of the preceding embodiments.

[0050] The present disclosure also relates to a method of manufacturing a composite panel, comprising at least: - a manufacturing step, during which at least one frame is produced by an additive manufacturing technique, in particular the frame comprising a plurality of bars extending in at least one direction of extension, in particular at least two different directions, in the frame reference frame so as to delimit cells, - a step of providing a filling material, during which at least one block of filling material is placed in at least one cell of the reinforcement, so as to obtain a core, and - a draping step, during which at least a first skin is draped over a first main surface of the core, and / or at least a second skin is draped over a second main surface of the core.

[0051] Such a manufacturing method thus makes it possible to obtain a composite panel according to the description, and therefore benefits from all the advantages set out above.

[0052] In some embodiments, the manufacturing method further comprises, before the step of providing a filling material, a step of cutting the filling material. The filling material can thus be supplied commercially in standard dimensions and then cut to the dimensions of the cells of the frame.

[0053] In some embodiments, the manufacturing method further comprises, before the draping step, a step of applying a film of glue to the skin. Such a film of glue may be supplied commercially in standard dimensions and then cut to the dimensions of the core.

[0054] In certain embodiments, the manufacturing method further comprises, after the step of applying a film of glue and before the draping step, a pre-gluing step, during which the skin equipped with the film of glue undergoes a cooking cycle. Such a pre-gluing step can be carried out under vacuum. It makes it possible to consolidate the film of glue on the skin before its final gluing on the core. Such a pre-gluing step is particularly suitable when the skin is a plate.

[0055] In some embodiments, the draping step is manual or automated.

[0056] In some embodiments, the manufacturing method further comprises, after at least the draping step, a step of cooking the core equipped with at least one skin, preferably both skins. The cooking step can be carried out under vacuum. It allows the skin to be consolidated on the core and therefore to consolidate and obtain the final composite panel.

[0057] In certain embodiments, the cooking step is carried out in an oven, under a press or in an autoclave.

[0058] In some embodiments, a forming sheet is attached against at least one skin during the baking step. This allows the position and shape of the skin to be maintained during the baking step. Such an option is particularly Particularly useful when the skin is flexible and likely to deform during cooking, for example when the skin is a sheet. However, since the skin is then blocked between the forming sheet and the rigid reinforcement of the core, more complex shaping tools, such as a forming mold, are not necessary.

[0059] In some embodiments, no shaping tooling is used during the firing step.

[0060] This composite panel is part of the ongoing research and development work on aircraft weight reduction, particularly through the materials used and the lighter on-board equipment. Such technological research efforts contribute to significantly improving the environmental performance of aircraft. Brief description of the drawings

[0061] The present invention will be better understood and the aforementioned characteristics and advantages will appear on reading the detailed description which follows, comprising examples of embodiments of the composite panel, the seat and the method of manufacturing a composite panel, 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 refers to the appended figures, in which: - [Fig.l] [Fig.l] is a sectional view of a first example of a composite panel according to the invention; - [Fig.2] [Fig.2] is a front view of the core of the first example of composite panel according to the invention; - [Fig.3] [Fig.3] is a sectional view of a second example of a panel composite according to the invention; - [Fig.4] [Fig.4] is a partial sectional view of a third example of composite panel according to the invention; - [Fig.5] [Fig.5] is a perspective view of a frame, in particular of a aircraft seat, according to the invention; - [Fig.6] [Fig.6] is a perspective view of a soul, in particular of a aircraft seat, according to the invention; - [Fig.7] [Fig.7] is a perspective view of an interior fitting, in particular of an aircraft seat, according to the invention. - [Fig.8] [Fig.8] is a perspective view of the equipment of [Fig.7] equipped with the borders according to the invention; - [Fig.9] [Fig.9] is a partial sectional view of a panel border composite according to the invention; and - [Fig. 10a] [Fig. 10b] [Fig. 10c] Figures 10a to 10c are sectional views partial of different modes of maintaining a filling material of the composite panel according to the invention.

[0062] The attached figures are schematic and are intended primarily to illustrate the principles of the presentation.

[0063] In the figures, identical elements or parts of elements are identified by the same reference signs. In addition, elements or parts of elements belonging to different embodiments, but having a similar function, are identified in the figures by numerical references incremented by 100, 200, etc. Description of the embodiments

[0064] In order to make the disclosure more concrete, examples of composite panels and aircraft seats are described in detail below, with reference to the appended figures. It is recalled that the invention is not limited to such examples.

[0065] [Fig.l] a sectional view of a first example of composite panel 1. The composite panel 1 comprises a core 10 and two skins 30a, 30b, in particular a first skin 30a and a second skin 30b, attached to each side of the core 10. Thus, the two skins 30a, 30b are attached against the two main faces 11a, 11b, in particular a first main face 11a and a second main face 11b, of the core 10.

[0066] At least one film of glue 40a, 40b, provided between the core 10 and the skins 30a, 30b, makes it possible to hold the skins 30a, 30b on the core 10.

[0067] The core 10 is also visible in [Fig.2] as a front view of the core 10 of the first example of composite panel 1.

[0068] The core 10 comprises a frame 12 comprising a plurality of bars 13 extending in at least one direction, in particular at least two distinct directions, in particular at least two orthogonal directions, according to the exemplary embodiment of [Fig.2].

[0069] The bars 13 intersect so as to form cells 14, in particular rectangular cells 14 according to the embodiment example of [Fig.2].

[0070] In particular, the reinforcement 12 runs along an edge of the core 10. According to such an arrangement, the cells 14 of the core 10 are therefore not laterally open to the outside.

[0071] According to an exemplary embodiment of the invention, the frame 12 is produced by additive manufacturing, in particular from polycarbonate (PC), polyetherimide (PEI), poly(phenylene sulfide) (PPS), polyethersulfone (PESU) and / or polyphenylsulfone (PPSU).

[0072] Alternatively, the frame 12 may possibly be made in several sub- additive manufacturing assemblies assembled after manufacturing.

[0073] All the external surfaces of the bars 13 may be solid, that is to say devoid of orifices, cells and / or even porosities. For example, main surfaces 15a, 15b of the frame 12 and peripheral surfaces 16 of the frame 12 are solid.

[0074] Alternatively, the bars 13 are devoid of external surfaces.

[0075] Furthermore, the frame 12 comprises an external structure consisting of main surfaces 15a, 15b, in contact with the skins 30a, 30b, and peripheral surfaces 16. Advantageously, the main surfaces 15a, 15b and the peripheral surfaces 16 of the frame 12 are solid, that is to say devoid of orifices, cells and / or even porosities.

[0076] The bars 13 of the frame 12 may be solid external structures. Thus, the bars 13 of the frame 12 are devoid of orifices, cells and / or even porosities on their external surfaces.

[0077] In addition, the frame 12 comprises an outer structure and an inner structure.

[0078] The internal structure of the frame 12 may be perforated. For this purpose, the bars 13 of the frame 12 may be of internal honeycomb structures.

[0079] Thus, at least a portion of the frame 12, in particular the bars 13, may comprise a honeycomb structure 17, such as internal cells 17. The honeycomb structure 17 is capable of being directly formed during additive manufacturing.

[0080] The volume of the honeycomb structure 17 represents at least 20%, in particular 100% of the total volume of the bars 13 concerned.

[0081] Alternatively, the frame 12, in particular the bars 13, may not comprise a honeycomb structure 17. In such a configuration, the volume of the honeycomb structure 17 represents 0% of the total volume of the bars 13 concerned.

[0082] The honeycomb structure 17 is directly formed during additive manufacturing. The honeycomb structure 17 can therefore be produced according to different available geometries.

[0083] The core 10 also comprises a filling material 20, in particular a honeycomb structure, for example made of synthetic fiber, such as an aramid paper impregnated with phenolic resin.

[0084] The filling material 20 may take the form of blocks filling the volume of the cells 14. A thickness of the filling material 20 is, in particular, at most equal to a thickness of the bars 13 forming the cell 14 concerned.

[0085] An example of a method for manufacturing such a composite panel 1 will now be described.

[0086] During a first step, the frame 12 is produced by additive manufacturing. In particular, each bar 13 can be separately manufactured by additive manufacturing. Subsequently, during an optional step, the bars 13 can be assembled together, in particular by clamping, screwing and / or gluing, in order to constitute the frame 12.

[0087] Then, the filling material 20 is provided, for example a honeycomb structure, is cut into several blocks according to the dimensions of all or part of the cells 14 and is installed respectively in the cell 14 concerned.

[0088] Then, two plates, in particular two consolidated thermoplastic composite plates, forming the skins 30a, 30b are provided and cover the two main faces 11a, 11b of the core 10.

[0089] Then, the glue films 40a, 40b, in particular two plies of glue, are cut to the dimensions of the core 10, and placed on an internal surface of each of the plates forming the skins 30a, 30b.

[0090] Then, a first cooking cycle is carried out in order to pre-glue the glue films 40a, 40b respectively on the corresponding plate forming the skins 30a, 30b. The first cooking cycle is carried out via a vacuum baking cycle.

[0091] Then, the two plates forming the skins 30a, 30b, equipped respectively with pre-glued adhesive films 40a, 40b, are draped, manually or automatically, on each main face 11a, 11b of the core 10.

[0092] Then, a second cooking cycle is carried out in order to consolidate the assembly thus formed. The second cooking cycle is carried out under vacuum, in an oven, under a press, or in an autoclave.

[0093] Since the plates forming the skins 30a, 30b are applied in a stable manner against the main surfaces 15a, 15b, in particular solid surfaces, of the frame 12, no shaping tooling is required during this cooking step. The composite panel 1 of [Fig.l] is thus obtained.

[0094] According to an alternative example, the skins 30a, 30b are not plates but pre-impregnated sheets. In such a case, the manufacturing method can be adapted as follows.

[0095] The steps of manufacturing the frame 12, cutting and installing the filling material 20 remain unchanged.

[0096] Next, two pre-impregnated sheets are provided and cut to the dimensions of the core 10. The two sheets can then be directly draped onto the core 10, without a prior pre-bonding step. The draping can be manual or automated.

[0097] Then, a cooking cycle similar to the first cooking example described previously is carried out in order to consolidate the assembly thus formed.

[0098] However, in such a case, a forming sheet can be temporarily attached against a free surface of each sheet, in order to ensure a hold and a position- operation of the tablecloths during cooking.

[0099] Once the cooking step is complete, the forming sheet can be removed. The composite panel 1 of [Fig.l] is then obtained.

[0100] [Fig.3] is a sectional view of a second example of composite panel 101 according to the invention.

[0101] The composite panel 101 comprises additional features compared to the first example described in relation to Figures 1 and 2.

[0102] The basic structure of the composite panel 101 remains, however, identical to that of the first example. Thus, the composite panel 101 comprises - a core 110, comprising a reinforcement 112, in particular produced by additive manufacturing, and a filling material 120, and - two skins 130a, 130b attached to each side of the core 110 using at least one film of glue 140a, 140b.

[0103] On the other hand, in the second example, at least one bar 113 of the frame 112 is solid and no longer honeycombed. The solid bar 113 then forms a reinforcement for the composite panel 101.

[0104] For example, several solid bars 113 can be provided at the edge of the composite panel 101, as shown in particular in [Fig.3].

[0105] In addition, at least one bar 113 comprises a solid portion 118 in which at least one niche 119 is arranged, in which at least one insert 150 can be integrated. Such an insert 150 may in particular be a fixing insert, capable of allowing fixing of elements added to the final composite panel 101.

[0106] In addition, at least one portion of the frame 112, in particular at least one bar 113, has a thickness greater than a thickness of at least one portion of the frame 112, in particular another bar 113, of the frame 112. Such a greater thickness makes it possible to vary the thickness of the composite panel 101. In particular, such bars 113 of greater thickness may protrude from the skins 130a, 130b. The bars 113 of greater thickness may in particular be provided at the edge of the composite panel 101, as shown in particular in [Fig. 3].

[0107] [Fig.4] is a partial sectional view of a third example of composite panel 201 according to the invention.

[0108] The basic structure of the composite panel 201 remains, however, identical to that of the first example. Thus, the composite panel 101 comprises - a core 210, comprising a reinforcement, not shown, in particular produced by additive manufacturing, and a filling material 220, and - two skins 230a, 230b attached to each side of the core 210 using at least one film of glue 240a, 240b.

[0109] In the third example, one of the bars 213 of the frame 212 has, in a plane transverse to a direction of extension, three branches 219a, 219b, 219c, in particular each in contact with a different block of filling material 220.

[0110] Figures 5 to 7 illustrate successive steps in the manufacture of interior equipment 301, in particular of an aircraft, such as a shell of an aircraft seat.

[0111] More specifically, figures 5, 6 and 7 are perspective views respectively of a frame 312, a core 310 and the interior equipment 301, in particular of an aircraft seat, according to the invention.

[0112] In a manner similar to what has been previously presented, the frame 312 is first manufactured, in particular by an additive manufacturing technique. Alternatively, the frame 312 may possibly be produced in several sub-assemblies manufactured by an additive manufacturing technique in a single-piece manner and then assembled after manufacture, to obtain the complete frame 312.

[0113] As can be seen in [Fig.5], the frame 312 is a three-dimensional arrangement.

[0114] According to an exemplary embodiment, the frame 312 may consist of an essentially two-dimensional structure which has nevertheless been curved to define a three-dimensional arrangement.

[0115] According to the embodiment example presented in [Fig.5], the frame 312 is curved, a first time, around a first axis of curvature A then curved, a second time, in the opposite direction, around a second axis of curvature B. The first axis of curvature A and the second axis of curvature B are in particular parallel and can correspond in practice to a vertical axis.

[0116] At least a portion of the bars 313 form edges of the frame 312 and follow the contours of the interior equipment 301, such as the shell of the aircraft seat.

[0117] At least one other portion of the bars 313, arranged internally of the frame 312, extends in a first direction of extension, in particular parallel to the first axis of curvature A and / or to the second axis of curvature B, and / or in a second direction of extension, in particular perpendicular to the first axis of curvature A and / or to the second axis of curvature B in a curvilinear reference frame of the frame 312.

[0118] The architecture of the bars 313 thus produced thus forms a plurality of cells 314.

[0119] As can be seen in [Fig.6], a filling material 320, in particular in the form of blocks of filling material, is then installed in all or part of the cells 314 of the frame 312, thus forming the core 310.

[0120] Finally, as can be seen in [Fig.7], a first skin 330a, also called front skin, and a second skin 330b, also called rear skin, can be attached and secured to the core 310, in particular according to the method presented previously, thus forming the interior equipment 301, in particular the aircraft seat shell.

[0121] [Fig.8] is a perspective view of the interior equipment 301 provided with a border 401. The border 401 can have different possible geometries depending on an expected finish.

[0122] According to the invention, the edge 401 is directly produced with the reinforcement constituting the core of the composite panel by an additive manufacturing technique.

[0123] [Fig.9] is a partial sectional view of the composite panel edge 401 according to the invention.

[0124] As previously explained, the reinforcement is produced by additive manufacturing. According to the invention, the edge 401 is also obtained by additive manufacturing, in the continuity of the manufacture of at least one of the reinforcements forming a final edge of the composite panel requiring finishing.

[0125] The edge 401 being obtained directly by additive manufacturing with the reinforcement, the bars of the reinforcement 12 on the ends of the composite panel are already obtained by additive manufacturing with the edge 401 forming a desired geometry for the expected finish.

[0126] Alternatively, the bars of the reinforcement 12 on the ends of the composite panel can be obtained by additive manufacturing with a desired shape and geometry for the expected finish, thus acting as an edge.

[0127] Such an arrangement makes it possible to replace all finishing steps provided until now, in particular providing for the installation of joints and / or finishing parts used for this function.

[0128] Figures 10a to 10c are partial sectional views of different modes of holding the filling material 20 of the composite panel 1.

[0129] According to the holding method presented in [Fig.10a], the filling material can be held by clamping between the bar of the composite panel reinforcement. For this purpose, the clamping can be achieved by a dimensional adjustment of the filling material and the cells of the composite panel.

[0130] According to the holding method presented in [Fig.10b], the filling material can be held by gluing to the bars of the reinforcement of the composite panel. For this purpose, the cells of the composite panel can comprise at least one rim 501, in particular obtained directly by additive manufacturing with the bars, intended to support the filling material. A film and / or glue dots 502 are arranged on an edge of the bar and / or on the rim 501, in order to ensure the holding of the filling material.

[0131] Finally, according to the holding mode presented in [Fig. 10c], the filling material can be maintained by mechanical fixing on the bars of the frame of the composite panel. For this purpose, the cells of the composite panel can comprise at least one rim 501, in particular obtained directly by additive manufacturing with the bars, intended to support the filling material. A fixing means 503, such as a screw and / or a pin, is through the filling material to be fixed on an edge of the bar and / or on the rim 501, in order to ensure the maintenance of the filling material.

[0132] Although the present invention has been described with reference to specific exemplary embodiments, it is obvious that modifications and changes may be made without departing from the general scope of the invention, as defined by the claims.

[0133] In particular, individual features of the various illustrated embodiments may be combined in additional embodiments. Therefore, the description and drawings should be considered in an illustrative rather than restrictive sense.

[0134] It is also obvious that all the characteristics described with reference to a method are transposable, alone or in combination, to a device, and conversely, all the characteristics described with reference to a device are transposable, alone or in combination, to a method.

Claims

Claims

1. Composite panel (1, 101, 201, 301), comprising - a core (10, 110, 210, 310), having at least a first main surface (11a) and a second main surface (11b), opposite each other, - a first skin (30a, 130a, 203a), applied against at least a part of the first main surface (11a) of the core (10, 110, 210, 310), and / or - a second skin (30b, 130b, 230b), applied against at least a part of the second main surface (11b) of the core (10, 110, 210, 310), wherein the core (10, 110, 210, 310) comprises at least one reinforcement (12, 112, 212, 312) comprising - at least one bar (13, 113, 213, 313) produced by additive manufacturing and extending in at least one direction of extension, and - a filling material (20, 120, 220, 320), filling at least one cell (14) of the frame (12, 112, 212, 312) delimited by the bar (13, 113, 213, 313).

2. A composite panel according to claim 1, wherein the core (310) is curved.

3. Composite panel according to claim 2, wherein at least one direction of extension of the bars (313) is parallel to a direction of curvature (A, B) of the core (310).

4. A composite panel according to any preceding claim, wherein the frame (12, 112, 212, 312) comprises several separate sub-assemblies manufactured by additive manufacturing and assembled together.

5. Composite panel according to any one of the preceding claims, wherein the first main surface (11a), respectively the second main surface (11b) of the reinforcement (12, 112, 212, 312), is solid.

6. A composite panel according to any preceding claim, wherein at least one peripheral surface of the frame (12, 112, 212, 312) is solid.

7. A composite panel according to any preceding claim, wherein at least one portion of the reinforcement (112) is of a thickness greater than a thickness of at least one other portion of the reinforcement (112).

8. A composite panel according to any preceding claim, wherein at least a portion of the frame (12, 112, 212, 312) has a honeycomb structure (17).

9. A composite panel according to any preceding claim, wherein at least a portion of the frame (12, 112, 212, 312) has a solid structure.

10. Composite panel according to any one of the preceding claims, wherein the frame (112) comprises at least one niche (119) configured to receive an insert (150).

11. Seat, in particular aircraft seat, comprising at least one composite panel (1) according to any one of the preceding claims.

12. A method of manufacturing a composite panel (1), comprising at least the following steps: - a manufacturing step, during which at least one reinforcement (12) is produced by an additive manufacturing technique, - a step of providing a filling material (20), during which at least one block of filling material (20) is placed in at least one cell (14) of the reinforcement (12), and - a draping step, during which at least one first skin (30a) is draped over a first main surface (11a) of the core (10) and / or at least one second skin (30b) is draped over a second main surface (11b) of the core (10).

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