Method for manufacturing an aerodynamic or hydrodynamic structure from composite material

Abstract

The invention relates to a manufacturing method (1) for obtaining any type of shape and size of aerodynamic or hydrodynamic structure incorporating an electronic device within its core. The multi-step design allows the electronic device to be placed and fixed to a first internal intermediate part manufactured beforehand, then the fabrication of the aerodynamic or hydrodynamic structure to be completed by filling an internal cavity of the first internal intermediate part with a filler material, before partially or completely overmolding the filled internal intermediate part. The aerodynamic or hydrodynamic structure thus obtained has an optimal external geometry because it is not affected by the presence of the electronic device within its core. Figure to be published with the abbreviation: Fig. 1

Description

Title of the invention: Method for manufacturing an aerodynamic or hydrodynamic structure made of composite material

[0001] The technical context of the present invention is that of aerodynamic and hydrodynamic structures designed in composite materials and active, that is to say incorporating one or more sensors or electronic equipment aimed at monitoring their operation or modifying their mechanical properties. More particularly, the invention relates to a method of manufacturing such an aerodynamic or hydrodynamic structure.

[0002] In the state of the art, the use of composite materials is known in many industrial fields, such as for example in the aeronautical field, the space field or even the maritime field. Such aerodynamic or hydrodynamic structures offer many advantages, among which we can cite lightness and high mechanical resistance. However, these advantages are obtained at the cost of more complex and often more expensive manufacturing processes than the manufacturing processes of equivalent metallic structures for example.

[0003] In particular, the integration of sensors or actuators within these aerodynamic or hydrodynamic structures is also known in order to measure certain metrics or to modify a local geometry for example. Such electronic components are usually placed on an external face of these aerodynamic or hydrodynamic structures, which is not always optimal. Indeed, when a very specific aerodynamic or hydrodynamic profile is sought, the presence of such sensors or actuators on the surface is not desired because it leads either to a deviation from the nominal profile, or it requires additional machining so that the external geometry of the aerodynamic or hydrodynamic structure takes into account the shape of the sensor or actuator. In all cases, the performance, either in use or in design and manufacturing, is not optimal.

[0004] The object of the present invention is to propose a new manufacturing method in order to respond at least to a large extent to the preceding problems and to further lead to other advantages.

[0005] In particular, the manufacturing method according to the invention aims to integrate electronic devices more simply, such as for example sensors and / or actuators within an aerodynamic or hydrodynamic structure made of a composite material, without affecting the external geometry - and therefore the aerodynamic profile - of said aerodynamic or hydrodynamic structure.

[0006] Another object of the invention is to facilitate the manufacture of aerody structures complex dynamic or hydrodynamic and equipped with integrated electronic devices.

[0007] Another aim of the invention is to facilitate the obtaining of aerodynamic or hydrodynamic profiles that are both complex and precise, despite the integration of electronic devices in such aerodynamic or hydrodynamic structures.

[0008] According to a first aspect of the invention, at least one of the aforementioned objectives is achieved with a method for manufacturing an aerodynamic or hydrodynamic structure made of a polymer matrix fiber composite material, and the geometry of its outer surface of which conditions its aerodynamic or hydrodynamic performance, this aerodynamic or hydrodynamic structure being instrumented by comprising at least one integrated electronic device which comprises at least one integrated sensor and / or actuator and associated electronic means, the manufacturing method comprising the following steps:

[0009] - a step of producing at least one intermediate part called interior, hollow, made of fibrous composite material with a polymer matrix, the function of which is to delimit an interior housing capable of receiving at least one electronic device and to serve as a mold;

[0010] - a step of depositing and fixing the at least one positioned electronic device in the interior housing;

[0011] - a covering step by depositing, shaping and polymerizing a polymer matrix fibrous composite material on all or part of the inner intermediate part, in order to obtain an aerodynamic or hydrodynamic outer part partially or completely covering the inner intermediate part, the outer part having a predetermined outer geometry, the aerodynamic or hydrodynamic structure comprising, at the end of the manufacturing process: the hollow inner intermediate part housing the at least one functional electronic device, and the aerodynamic or hydrodynamic outer part overmolding all or part of the inner intermediate part.

[0012] In the context of the present invention, the aerodynamic or hydrodynamic structure obtained by the manufacturing method according to the invention is a monolithic aerodynamic or hydrodynamic structure, i.e. a single-piece structure. Thus, no part of the aerodynamic or hydrodynamic structure obtained by the manufacturing method according to the invention can be separated or detached from said aerodynamic or hydrodynamic structure without the latter being destroyed or damaged. In the context of the present invention, the inner intermediate part forms a core for the aerodynamic or hydrodynamic structure.

[0013] In the context of the present invention, a composite material is a material comprising a matrix and a filler of synthetic material. For example, the matrix comprises a plastic material and the composite material filler comprises glass fibers or particles, for example in the form of fibers, nanotubes or any other shapes. By way of non-limiting example, the matrix is ​​formed from a non-metallic and non-ceramic material.

[0014] In the context of the present invention, the at least one electronic device is of the type of a sensor and / or an actuator advantageously connected to the sensor(s). Generally speaking, the at least one electronic device comprises any type of sensor and / or electronic and / or mechanical and / or optical actuator miniaturized and configured to be integrated into the aerodynamic or hydrodynamic structure. By way of non-limiting example, the at least one electronic device comprises a strain gauge, a piezoelectric sensor, a piezoelectric actuator, a microelectromechanical system, etc. Furthermore, the at least one electronic device is optionally associated with electrical connection means, such as, for example, electrical wires and / or wireless communication means, such as, for example, an RFID chip or a radio transmitter.

[0015] In the context of the present invention, at the end of the manufacturing method according to the invention, the at least one electronic device is embedded in the composite material forming the aerodynamic or hydrodynamic structure. To this end, during the deposition step, the at least one electronic device is advantageously fixed or attached or associated with an inner wall of the inner intermediate part.

[0016] In the context of the present invention, during the covering step, the inner intermediate part serves as a production support for the outer part. Also, the choice of the composite material is made so as to guarantee the physical and / or functional integrity of the at least one electronic device during the covering step, in particular with regard to a polymerization temperature for example, or a pressure applied during the manufacturing process in accordance with the first aspect of the invention.

[0017] Thus, the manufacturing method according to the first aspect of the invention makes it possible to provide internal surfaces for the final aerodynamic or hydrodynamic structure and accessible during the manufacturing method, i.e. after the production step and before the covering step, on which internal surfaces the at least one electronic device is affixed, before obtaining the final geometry of the aerodynamic or hydrodynamic structure. Access to these internal surfaces thus allows the positioning, installation, possible fixing and, if necessary, wiring of the at least one electronic device.

[0018] The manufacturing method according to the first aspect of the invention thus makes it possible to obtain more homogeneous aerodynamic or hydrodynamic structures, by limiting the appearance of structural weaknesses, such as for example bonding points, drilling zones as known on known aerodynamic or hydrodynamic structures. In other words, during the manufacturing process according to the invention, the external part is intended to consolidate the aerodynamic or hydrodynamic structure so as to allow a recovery of mechanical forces on the one hand, and on the other hand so as to obtain an optimal geometry with regard to aerodynamic or hydrodynamic constraints.

[0019] For this purpose, the manufacturing method according to the first aspect of the invention proposes a segmentation of the manufacturing steps: the production step and the covering step, but also the step of depositing the at least one electronic device between the production step and the covering step. Of course, the production step requires first determining one or more separation axes making it possible to obtain the internal intermediate part(s) which will define deposition surfaces for the at least one electronic device, before assembly, covering and design of the final external envelope of the aerodynamic or hydrodynamic structure.

[0020] The manufacturing method according to the first aspect of the invention thus makes it possible to design aerodynamic or hydrodynamic structures whose dynamic performances are optimized, both from an aerodynamic and hydrodynamic point of view.

[0021] The manufacturing method according to the first aspect of the invention solves the technical problem in that it makes it possible to obtain - in a particularly innovative and clever manner - an aerodynamic or hydrodynamic structure during which the at least one electronic device is embedded in the heart of the composite material forming the final aerodynamic or hydrodynamic structure. The manufacturing method according to the first aspect of the invention implements particular steps which are coordinated with each other so as not to harm the embedded electronic device, in particular.

[0022] The manufacturing method according to the first aspect of the invention thus proposes to temporarily provide access to interior faces of the final aerodynamic or hydrodynamic structure in order, during the manufacturing method, to position there and securely fix there the at least one electronic device chosen for integration. The different steps of the manufacturing method according to the first aspect of the invention make it possible to maintain the dynamic performance of the final aerodynamic or hydrodynamic structure without penalizing its future framework of use.

[0023] To this end, more particularly, the manufacturing method in accordance with the first aspect of the invention makes it possible, in particular via the covering step, to guarantee continuity of the surface fibers of the composite material forming the aerodynamic or hydrodynamic structure. This continuity of surface fibers makes it possible, in its tower, to obtain a continuum of homogeneous material allowing not to alter the mechanical performances nor to disturb the fluidic flows around the final aerodynamic or hydrodynamic structure.

[0024] In one embodiment, the inner intermediate part(s) and the outer part are manufactured by the same method of laminating layers of fibers chosen, the outer part completely covers the intermediate part(s), the continuity of the fibers of the composite material being ensured on the surface of the composite material of the intermediate part(s) and on the surface of the composite material of the outer part.

[0025] The manufacturing method according to the first aspect of the invention advantageously comprises at least one of the improvements below, the technical characteristics forming these improvements being able to be taken alone or in combination:

[0026] - the manufacturing method comprises a step of filling the interior housing of the inner intermediate part by a filling material, this step respecting the positioning of the at least one electronic device, the aerodynamic or hydrodynamic structure comprising at the end of the manufacturing process: the hollow inner intermediate part housing the at least one electronic device, the filling material, and the outer aerodynamic or hydrodynamic part overmolding all or part of the inner intermediate part, the filling material allowing the mechanical forces to be taken up with the outer part. This advantageous configuration makes it possible to improve the mechanical resistance of the aerodynamic or hydrodynamic structure;

[0027] - the filling step comprises a step of injecting and hardening the filling material which comprises an expanding foam and / or a resin, this injection and curing step being carried out in the interior housing in order to fill it, after the step of depositing and fixing the at least one electronic device and before the covering step, a curing temperature of the filling material being chosen so as not to damage the at least one electronic device. In particular, the curing temperature is for example between 30°C and 200°C. This temperature range is optimal for preserving the at least one electronic device during the implementation of the manufacturing method according to the invention;

[0028] - the manufacturing process involves the production of several intermediate parts hollow interiors assembled together, for example by crosslinking an adhesive. Thus, this advantageous configuration makes it possible to make interior faces of the aerodynamic or hydrodynamic structure accessible to the deposition of at least one electronic device, by the manufacture of the non-structural interior intermediate parts. These interior intermediate parts are intended to be assembled together to each other and used as a molding support for the application of the outer part during the covering step. In other words, these inner intermediate parts play the role of an internal lost mold for the aerodynamic or hydrodynamic structure finally manufactured. These inner intermediate parts are not used to absorb mechanical forces. Advantageously, only the outer part and the filling material injected inside the hollow inner intermediate parts are used to absorb structural mechanical forces. One of the innovations of this manufacturing process thus lies in the use of support parts - the inner intermediate parts - which allow both the integration of electronic devices, but also the shaping of a predetermined outer geometry of the final aerodynamic and hydrodynamic structure.In particular, several hollow interior intermediate parts are produced, assembled together so as to house the electronic device before their assembly and to serve as a mold for the exterior part once assembled, these hollow interior intermediate parts being fixed for example by crosslinking an adhesive; .

[0029] - in particular, the step of producing at least one interior intermediate part involves the production of at least two half-shells, then a step of bonding and sealing the two half-shells together, for example using an epoxy glue whose polymerization temperature is chosen so as to respect the physical and functional integrity of the at least one electronic device, the two half-shells thus bonded delimiting between them the internal housing in which the at least one electronic device will be housed.

[0030] - Generally speaking, the interior intermediate parts can be made laminated by different methods of laminating composite fiber layers, such as for example by molding, by contact, by infusion, by injection or by lamination on a support taking the form of a simple mold or a combination of an assembly formed by a mold and a counter-mold, in order to obtain the final aerodynamic and hydrodynamic structure while controlling a number of fiber layers and predetermined dimensions; the inner intermediate part(s) and the outer part are manufactured so as to ensure the continuity of the fibers of the composite material being ensured on the surface of the composite material of the intermediate part(s) and on the surface of the composite material of the outer part; advantageously, according to the invention, the use of inner intermediate parts serving as a lost mold is distinguished from known manufacturing methods;

[0031] - the outer part has the same shape as that of all or part of a outer surface of the at least one inner intermediate piece, the covering step allowing the inner surface of the outer piece to fit an outer surface of the at least one inner intermediate piece;

[0032] - the bonding step is of the type of bonding by epoxy glue, the two half- shells being glued to each other at peripheral edges located opposite each other;

[0033] - according to a preferred embodiment of the invention, the outer part is formed of the same composite material as that of the inner intermediate piece. Alternatively, the outer piece is formed of a composite material different from that forming the at least one inner intermediate piece;

[0034] - the outer part and the inner intermediate part are formed from the same composite material, the outer part and the inner intermediate part possibly having a different number of layers, and / or different thicknesses, and / or different fiber orientations and / or different mechanical properties. In particular, according to a preferred embodiment, an orientation of the fibers of the composite material of the at least one inner intermediate part is inclined relative to the orientation of the fibers of the composite material of the outer part. By way of example, the orientation of the fibers of the composite material of the at least one inner intermediate part is for example oriented at 90° relative to that of the fibers of the composite material of the outer part;

[0035] - the polymerization step of the covering step is carried out at a temperature polymerization process allowing the integrity of at least one electronic device to be maintained, the polymerization temperature being less than 150°. This advantageous configuration makes it possible to optimize the manufacturing process and to guarantee optimal subsequent operation of the electronic device;

[0036] - the inner intermediate part and / or the outer part are manufactured by a method of laminating layers of fibers chosen from the following methods: contact molding, infusion, injection, vacuum molding, molding on a support. For example, the hollow intermediate part which is produced by shaping and polymerizing the structural fiber composite material with a polymer matrix in a mold. In addition, by way of non-limiting example, the molding on a support can use a single mold or double mold, or a combination of an assembly formed by a mold and a counter-mold. In particular, the inner intermediate part(s) and the outer part are manufactured by the same method of laminating layers of fibers chosen, the outer part completely covers the intermediate part(s), the continuity of the fibers of the composite material being ensured on the surface of the composite material of the intermediate part(s) and on the surface of the composite material of the outer part;

[0037] - the step of depositing, positioning and fixing the at least one electronic device electronics in the interior housing is made using a template in order to position it in a predetermined configuration. In particular, the at least one device electronic device is securely attached to a peripheral surface of the inner intermediate part of the aerodynamic or hydrodynamic structure. Preferably, each at least one electronic device is bonded to a peripheral surface of the inner intermediate part.

[0038] - the depositing and fixing step comprises a step of placing and fixing electronic means comprising in particular at least one electrical connection wire of the at least one electronic device on the inner intermediate part of the aerodynamic or hydrodynamic structure, and in which a step of drilling a hole is carried out so that one end of the at least one distal electrical connection wire of said electronic device is located outside the aerodynamic or hydrodynamic structure. Indeed, in the case where the at least one electronic device requires a wired connection, it is then necessary to bring out electrical connection wires outside the aerodynamic or hydrodynamic structure. The correct positioning of the electrical connection wires on the at least one inner intermediate part and their fixing on said inner intermediate part makes it possible to reduce the risks of tearing or damage during subsequent use of the final aerodynamic or hydrodynamic structure;

[0039] - the hole drilling step is preferably carried out before the re-cutting step. covering, possibly after;

[0040] - one or more injection points allow a resin or foam to be injected in the interior intermediate housing, said resin or said foam forming the filling material;

[0041] - outer surfaces of the intermediate piece act as support surfaces of mold for the covering step, the polymerized composite material being positioned inside a second peripheral mold which delimits an external geometry of the aerodynamic or hydrodynamic structure;

[0042] - the covering step comprises (i) a step of covering the inter part interior intermediate part of the aerodynamic or hydrodynamic structure by at least one ply comprising a synthetic filler from which the composite material is formed, the ply being applied to the interior intermediate part of the aerodynamic or hydrodynamic structure, (ii) a step of applying a matrix to the at least one ply, (iii) a polymerization step;

[0043] - the step of applying the matrix is ​​of the type of an infusion step, a step injection or contact molding step;

[0044] - the at least one electronic device has an anti-vibration function. In par In particular, the at least one electronic device is of the type of a piezoelectric element associated with a dissipative circuit which carries out an electromechanical conversion aimed at reducing the vibration amplitude of the aerodynamic or hydrodynamic structure in operation. This advantageous configuration allows the conversion of mechanical energy - such as local deformation of the aerodynamic or hydrodynamic structure obtained by the manufacturing process - into electrical energy. This property of the piezoelectric material can be used in a clever way to reduce vibrations of the aerodynamic or hydrodynamic structure obtained by the manufacturing process during its subsequent use. This clever configuration thus makes it possible to extend the range of use of the aerodynamic or hydrodynamic structure obtained by the manufacturing process, in terms of speeds or mechanical or dynamic stresses for example.Consequently, the possibility of being able to dissipate certain excitation frequencies of the aerodynamic or hydrodynamic structure obtained by the manufacturing process makes it possible to relax specifications during the design of such an aerodynamic or hydrodynamic structure and to consider new geometries or the use of less efficient - therefore more economical - or more durable composite materials;

[0045] - the structural fibrous composite material with polymer matrix is ​​a material composite composed of a matrix with carbon fibers and / or with glass fibers.

[0046] According to a second aspect of the invention, there is provided an aerodynamic or hydrodynamic structure made of structural fibrous composite material with a polymer matrix, obtained by the manufacturing method in accordance with the first aspect of the invention or according to any of its improvements, the aerodynamic or hydrodynamic structure comprising:

[0047] - a hollow interior intermediate piece made of fiber matrix composite material polymeric, housing at least one electronic device inside its internal housing,

[0048] - an aerodynamic or hydrodynamic exterior part made of composite material polymer matrix fibrous material enveloping the hollow inner intermediate piece and whose inner surface matches the outer surface of the hollow inner intermediate piece.

[0049] Thus, the aerodynamic or hydrodynamic structure in accordance with the second aspect of the invention and obtained by the manufacturing method in accordance with the first aspect of the invention has increased performance in terms of external geometric qualities, and therefore of aerodynamic or hydrodynamic profile, in terms of manufacturing costs and dynamic performance. These performances result directly from the integration at the heart of the aerodynamic or hydrodynamic structure of the electronic device, and from perfect control of the geometry of the composite material applied during the application of the external part on the at least one part inner intermediate.

[0050] The aerodynamic or hydrodynamic structure in accordance with the second aspect of the invention advantageously comprises at least one of the improvements below, the technical characteristics forming these improvements being able to be taken alone or in combination:

[0051] - the hollow interior intermediate part(s) have a filling material pleating, the filling material absorbing the mechanical forces with the aerodynamic or hydrodynamic exterior part, the filling material being for example an expanding foam or a resin;

[0052] - the aerodynamic or hydrodynamic structure is used in the fields following techniques: maritime, aeronautics, automotive, rail, wind, space, defense;

[0053] - the at least one electronic device is chosen from a thermal sensor, a strain gauge, a piezoelectric element, an optical fiber, an accelerometer;

[0054] - the at least one electronic device has an anti-vibration function, the at least one at least one electronic device being of the type of a piezoelectric element or a strain gauge;

[0055] - according to a first embodiment variant, the aerodynamic or hydro structure dynamic has a wing shape, and is for example an airplane wing, or a wind turbine wing. According to a second embodiment, the aerodynamic or hydrodynamic structure is a constituent element of a boat, for example a hull, a foil, a mast, a rudder of a windsurfing board, surfboard, windsurfing or boat.

[0056] - the structural fibrous composite material with polymer matrix is ​​a material composite composed of a matrix comprising carbon fibers and / or glass fibers.

[0057] The process of integrating the sensors / actuators within the composite material is coupled with the control of the implementation processes. The proposed manufacturing process is centered on access to the interior faces of the part to position, glue, and wire the actuators or sensors chosen for integration. Preserving the dynamic performance of the structure is necessary so as not to affect its use. The continuity of the surface fibers in order to obtain a continuum of homogeneous material so as not to alter the mechanical performance or disturb the fluid flows (air, water, etc.) is a major issue in the specifications. The manufacturing process and its implementation are in line with these requirements. Access to the interior faces is made possible by the manufacture of non-structural intermediate parts.These intermediate pieces are then assembled and used as a casting support (and can be seen as a lost mold internal to the structure). The innovation of this manufacturing process lies in the use of parts. intermediate supports allowing the integration of components and the shaping of the final geometry of the product. Generally speaking, composite parts are manufactured in industry by different methods of layering fiber layers (contact molding, infusion, injection, lamination, etc.) on a support (single mold or combination of a mold and counter-mold assembly) in order to obtain a final part (number of layers and desired dimensions). The use of intermediate parts serving as a lost mold distinguishes the proposed process from conventional shaping processes

[0058] Various embodiments of the invention are provided, integrating according to all of their possible combinations the different optional characteristics set out here.

[0059] Other characteristics and advantages of the invention will become apparent from the following description on the one hand, and from several examples of embodiment given for informational and non-limiting purposes with reference to the attached schematic drawings on the other hand, in which:

[0060] [Fig-1] illustrates a block diagram of the assembly process in accordance with first aspect of the invention;

[0061] [Fig.2] illustrates a schematic view of a first stage of an example of a rea implementation of the assembly process illustrated in [Fig.l];

[0062] [Fig.3] illustrates a schematic view of a second stage of an example of a rea implementation of the assembly process illustrated in [Fig.l];

[0063] [Fig.4] illustrates a schematic view of a third stage of an example of a rea implementation of the assembly process illustrated in [Fig.l];

[0064] [Fig.5] illustrates a schematic view of a fourth step of an example of a rea implementation of the assembly process illustrated in [Fig.l];

[0065] [Fig.6] illustrates a schematic view of a fifth step of an example of a rea lization of the assembly process illustrated in [Fig.l].

[0066] [Fig.7] illustrates a schematic overview of the manufacturing process according to the invention.

[0067] Of course, the features, variants and different embodiments of the invention may be combined with each other, in various combinations, provided that they are not incompatible or mutually exclusive. In particular, variants of the invention may be imagined comprising only a selection of features described below in isolation from the other features described, if this selection of features is sufficient to confer a technical advantage or to differentiate the invention from the state of the prior art.

[0068] In particular, all the variants and all the embodiments described are com- can be combined with each other if there is nothing technically preventing this combination.

[0069] In the figures, the elements common to several figures retain the same reference.

[0070] With reference to FIGURES 1 to 7, the invention relates to a manufacturing method 1 of an aerodynamic or hydrodynamic structure 2 made of a fibrous composite material with a polymer matrix 250, and of which a geometry of its external surface conditions its aerodynamic or hydrodynamic performances, this aerodynamic or hydrodynamic structure 2 being instrumented by comprising at least one integrated electronic device 22, the manufacturing method 1 comprising the following steps:

[0071] - a step 11 of producing at least one intermediate part 21 A, 21B called in interior, made of polymer matrix fibrous composite material 250, the interior intermediate part being hollow and delimiting an interior housing 211 capable of receiving at least one electronic device 22;

[0072] - a step 12 of depositing and fixing the at least one electronic device 22 in housing 211 interior;

[0073] - a covering step 13 by depositing, shaping and polymerizing a polymer matrix fibrous composite material 250 on all or part of the inner intermediate part, in order to obtain an aerodynamic or hydrodynamic outer part 25 partially or completely covering the inner intermediate part 21 A, 21B, the outer part 25 having a predetermined outer geometry, the aerodynamic or hydrodynamic structure 2 comprising, at the end of the manufacturing method 1: the hollow inner intermediate part 21A, 21B housing the at least one electronic device 22, and the aerodynamic or hydrodynamic outer part 25 overmolding all or part of the inner intermediate part.

[0074] FIGURES 2 to 6 illustrate an example of implementation of the manufacturing method 1 according to the invention. [Fig.7] illustrates another example of implementation of the manufacturing method 1 according to the invention, applied to the manufacture of a water wing for a maritime vehicle.

[0075] [Fig. 2] illustrates a first step of the manufacturing method 1, corresponding to the production step 11. Here, the production step 11 consists of the production of two interior intermediate parts 21A, 21B: a first interior intermediate part 21A and a second interior intermediate part 21B. At least one of the first interior intermediate part 21A and the second interior intermediate part 21B delimits an interior housing 211 capable of receiving the electronic device 22.

[0076] The first inner intermediate piece 21A and the second inner intermediate piece 21B are both made of a composite material. In particular, advantageously, the composite material is applied in such a manner that fibers of said composite material are oriented according to a first orientation.

[0077] The first inner intermediate piece 21A and the second inner intermediate piece 21B are placed opposite each other, so that a contact surface 210 (or connecting surface or assembly surface) of each first inner intermediate piece 21A and second inner intermediate piece 21B are located opposite each other. The bearing faces 210 are complementary to each other in order to allow subsequent assembly of the two inner intermediate pieces 21A, 21B against each other.

[0078] [Fig. 3] illustrates a second step of the manufacturing method 1 according to the invention, corresponding to the step 12 of depositing and fixing an electronic device 22 in the interior housing 211 of one of the two interior intermediate parts 21A, 21B. More particularly, the electronic device 22 is placed in the second interior intermediate part 21B, so that said electronic device 22 is brought into contact or connected against an interior face 212 of said second interior intermediate part 21B.

[0079] An electrical connection wire 23 of the electronic device 22 extends partly inside the inner intermediate pieces and partly outside them. For this purpose, the first inner intermediate piece 21A has a through hole to allow the electrical connection wire 23 to be extended outside the inner housing 211 delimited by the two inner intermediate pieces 21A, 21B.

[0080] As a result, the two inner intermediate pieces 21A, 21B are brought together, according to the arrow shown schematically in [Fig.3], in order to place the bearing face 210 of the first inner intermediate piece 21A in contact and in support - or in connection - against the bearing face 210 of the second inner intermediate piece 21B.

[0081] [Fig. 4] illustrates a third step of the manufacturing method 1 according to the invention, corresponding to the fixing of the two intermediate parts 21A, 21B against each other at their bearing face 210. [Fig. 4] corresponds to a bonding and sealing step of the production step 11 in the manufacturing method 1 according to the invention: a strip of glue is for example applied to one and / or the other of the bearing faces 210 of the inner intermediate parts 21A, 21B and then said inner intermediate parts 21A, 21B are pressed against each other. This assembly thus makes it possible - depending on the bearing faces 210 considered - to achieve such a sealed fixing of the two inner intermediate parts 21A, 21B.

[0082] Optionally, this bonding step gives rise to the appearance of a peripheral bead 214 corresponding to a glue joint of the two intermediate parts 21A, 21B inside each other. In a particularly advantageous manner and specific to the invention, the presence of this bead 214 is not detrimental to obtaining a optimal aerodynamic or hydrodynamic structure 2 since the manufacturing process 1 of such an aerodynamic or hydrodynamic structure 2 is not yet complete. On the contrary, the interior intermediate parts 21A, 21B thus assembled against each other only form a core for the future aerodynamic or hydrodynamic structure 2, which core will then be covered by another composite material as will be specified with reference to [Fig.6].

[0083] [Fig. 5] illustrates a fourth step of the manufacturing method 1 according to the invention, corresponding to a step of filling the inner housing 211 delimited by the inner intermediate parts 21A, 21B with a filling material 24. The filling of the inner housing 211 with such a filling material 24 aims to optimize the rigidity of the future aerodynamic or hydrodynamic structure 2 and / or to optimize its density. In addition, the filling step is carried out while taking care to guarantee the physical and functional integrity of the electronic device 22 placed in the inner housing 211. For this purpose, the filling step comprises a step of injecting and hardening the filling material 24 in the inner housing 211, via the opening 213 provided on the first inner intermediate part 21A.

[0084] With reference to the diagram shown in [Fig.5] and which represents a curve of evolution FX of the temperature T°C and the pressure P over the time dt, during the injection of the filling material 24 into the interior housing 211, such that, throughout the duration of the filling step, the temperature T°C and the pressure P prevailing inside the interior housing 211 do not exceed a maximum MX defined by the electronic device 22 itself.

[0085] Advantageously, the filling material 24 is of the expanding foam and / or resin type. By way of non-limiting example, a hardening temperature T°C of the filling material 24 is between 30°C and 200°C, and preferably less than 150°C.

[0086] [Fig. 6] illustrates a fifth step of the manufacturing method 1 according to the invention, corresponding to the covering step 13 by depositing, shaping and polymerizing a polymer matrix fibrous composite material 250 on a peripheral periphery of the inner intermediate parts 21A, 21B, in order to obtain an aerodynamic or hydrodynamic outer part 25 covering - here completely - the inner intermediate parts 21A, 21B. In a particularly advantageous manner, the outer part 25 then has a predetermined and perfectly controlled outer geometry during the covering step 13. In particular, the covering step 13 makes it possible to cover the peripheral bead 214 which had been formed during the step of fixing the two intermediate parts 21A, 21B against each other at their bearing face 210: the outer face of the outer part 25 thus affixed to and against the interior intermediate parts 21 A, 21B no longer presents any abrupt variation in thickness or geometry: it presents a smooth outline and the shapes and dimensions of which are perfectly controlled during the implementation of the covering step 13.

[0087] The covering step 13 advantageously uses a composite material whose fibers are oriented according to a second orientation different from the first orientation of the fibers of the composite material of the interior intermediate parts 21A, 21B, in order to increase the rigidity of the aerodynamic or hydrodynamic structure 2 thus obtained by the manufacturing method 1.

[0088] Thus, the manufacturing method 1 according to the invention makes it possible to obtain any type of shape and dimension of an aerodynamic or hydrodynamic structure 2 incorporating an electronic device 22 in its core. The multi-step design makes it possible to place and fix the electronic device 22 at the level of a first internal intermediate part 21A manufactured beforehand, then to finalize the manufacturing of the aerodynamic or hydrodynamic structure 2 by filling an internal housing 211 of the first internal intermediate part 21A with a filling material 24, before partially or totally overmolding the internal intermediate part thus filled. The aerodynamic or hydrodynamic structure 2 thus obtained has an optimal external geometry because it is not impacted by the presence of the electronic device 22 in its core.

[0089] Of course, the invention is not limited to the examples which have just been described and numerous adjustments can be made to these examples without departing from the scope of the invention. In particular, the different characteristics, forms, variants and embodiments of the invention can be associated with each other in various combinations insofar as they are not incompatible or mutually exclusive. In particular, all the variants and embodiments described above can be combined with each other.

Claims

Claims

1. Method for manufacturing (1) an aerodynamic or hydrodynamic structure (2) made of polymer matrix fibrous composite material (250), and of which a geometry of its external surface conditions its aerodynamic or hydrodynamic performances, this aerodynamic or hydrodynamic structure (2) being instrumented by comprising at least one integrated electronic device (22) which comprises at least one integrated sensor and / or actuator and associated electronic means, the manufacturing method (1) comprising the following steps: - a step of producing (11) at least one intermediate part (21 A, 21B) called internal, hollow, made of polymer matrix fibrous composite material (250), and the function of which is to delimit an internal housing (211) capable of receiving the at least one electronic device (22) and of serving as a mold;- a step of depositing (12) and fixing the at least one electronic device (22) positioned in the interior housing (211); - a covering step (13) by depositing, shaping and polymerizing a fibrous composite material with a polymer matrix (250) on all or part of the interior intermediate part (21A, 21B), in order to obtain an aerodynamic or hydrodynamic exterior part (25) partially or completely covering the interior intermediate part (21A, 21B), the exterior part (25) having a predetermined exterior geometry, the aerodynamic or hydrodynamic structure (2) comprising, at the end of the manufacturing method (1): the hollow interior intermediate part (21A, 21B) housing the at least one functional electronic device (22), and the aerodynamic or hydrodynamic exterior part (25) overmolding all or part of the interior intermediate part (21A, 21B).;

2. Manufacturing method (1) according to the preceding claim, in which several hollow interior intermediate parts (21A, 21B) are produced, assembled together so as to house the electronic device before their assembly and to serve as a mold for the exterior part once assembled, these hollow interior intermediate parts (21A, 21B) being fixed for example by crosslinking an adhesive.

3. A manufacturing method (1) according to any preceding claim, wherein the manufacturing method (1) comprises a step of filling the interior housing (211) of the inter- intermediate (21A, 21B) interior by a filling material (24), this step respecting the positioning of the at least one electronic device (22), the aerodynamic or hydrodynamic structure (2) comprising at the end of the manufacturing process (1): the hollow interior intermediate part (21A, 21B) housing the at least one electronic device (22), the filling material (24), and the aerodynamic or hydrodynamic exterior part (25) overmolding all or part of the interior intermediate part (21A, 21B), the filling material (24) allowing the mechanical forces to be taken up with the exterior part (25).

4. Manufacturing method (1) according to the preceding claim, wherein the filling step comprises a step of injecting and curing the filling material (24) which comprises an expanding foam and / or a resin, this injection and curing step being carried out in the interior housing (211) in order to fill it, after the step of depositing (12) and fixing the at least one electronic device (22) and before the covering step (13), a temperature (T°C) for curing the filling material (24) being chosen so as not to damage the at least one electronic device (22), and possibly for example being between 30°C and 200°C.

5. Manufacturing method (1) according to any one of the preceding claims, in which the step of producing (11) the at least one internal intermediate part (21A, 21B) comprises producing at least two half-shells, then a step of bonding and sealing the two half-shells together, for example using an epoxy glue whose polymerization temperature (T°C) is chosen so as to respect the physical and functional integrity of the at least one electronic device (22), the two half-shells thus bonded delimiting between them the internal housing (211) in which the at least one electronic device (22) will be housed.

6. Manufacturing method (1) according to any one of the preceding claims, in which the outer part (25) has the same shape as that of all or part of an outer surface of the at least one inner intermediate part (21A, 21B), the covering step (13) allowing the inner surface of the outer part (25) to match the outer surface of the inner intermediate part(s) (21A, 21B).

7. Manufacturing method (1) according to any one of the claims previous, in which the outer part (25) is formed from the same composite material as that of the inner intermediate part (21A, 21B).

8. Manufacturing method (1) according to the preceding claim, in which the outer part (25) and the inner intermediate part (21A, 21B) are formed from the same composite material, the outer part (25) and the inner intermediate part (21A, 21B) possibly having a different number of layers, and / or different thicknesses, and / or different fiber orientations and / or different mechanical properties.

9. Manufacturing method (1) according to any one of the preceding claims, wherein the polymerization step of the covering step (13) is carried out at a polymerization temperature (T°C) making it possible to maintain the integrity of the at least one electronic device (22), the polymerization temperature (T°C) being less than 150°.

10. Manufacturing method (1) according to any one of the preceding claims, in which the inner intermediate part (21A, 21B) and / or the outer part (25) are manufactured by a method of laminating layers of fibers chosen from the following methods: contact molding, infusion, injection, vacuum molding, molding on a support.

11. Manufacturing method (1) according to any one of the preceding claims, in which the inner intermediate part(s) (21A, 21B) and the outer part (25) are manufactured by the same method of laminating layers of fibers chosen, the outer part completely covers the intermediate part(s), the continuity of the fibers of the composite material being ensured on the surface of the composite material of the intermediate part(s) and on the surface of the composite material of the outer part (25).

12. Manufacturing method (1) according to any one of the preceding claims, wherein the step of depositing (12), positioning and fixing the at least one electronic device (22) in the interior housing (211) is carried out using a template in order to position it in a predetermined configuration.

13. Manufacturing method (1) according to the preceding claim, in which the step of depositing (12) and fixing comprises a step of positioning and fixing electronic means comprising in particular at least one electrical connection wire (23) of the at least one electronic device (22), i.e. for example of the sensor and / or the actuator, on the internal intermediate part (21A, 21B) of the aerodynamic or hydrodynamic structure (2), and in which a step of drilling a hole is carried out so that one end of the at least one electrical connection wire (23) distal to said electronic device (22) is located outside the aerodynamic or hydrodynamic structure (2).

14. Manufacturing method (1) according to claim 12, wherein one or more injection points allow a resin or a foam to be injected into the interior intermediate housing (211), said resin or said foam forming the filling material (24).

15. A manufacturing method (1) according to any preceding claim, wherein outer surfaces of the intermediate part (21A, 21B) act as mold support surfaces for the covering step (13), the polymerized composite material being positioned inside a second peripheral mold which delimits an outer geometry of the aerodynamic or hydrodynamic structure (2).

16. Manufacturing method (1) according to any one of claims 1 to 14, wherein the covering step (13) comprises: - a covering step (13) of the inner intermediate part (21A, 21B) of the aerodynamic or hydrodynamic structure (2) with at least one ply comprising a synthetic filler of which the composite material is formed, the ply being applied to the inner intermediate part (21A, 21B) of the aerodynamic or hydrodynamic structure (2); - a step of applying a matrix to the at least one ply; - a polymerization step.

17. Manufacturing method (1) according to any one of the preceding claims, wherein the at least one electronic device (22) has an anti-vibration function and / or the electronic device (22) is of the type of a piezoelectric element associated with a dissipative circuit which carries out an electromechanical conversion aimed at reducing the vibration amplitude of the aerodynamic or hydrodynamic structure (2) in operation.

18. A manufacturing method (1) according to any preceding claim, wherein the structural fibrous composite material polymer matrix is ​​a composite material composed of a matrix with carbon fibers and / or with glass fibers.

19. Aerodynamic or hydrodynamic structure (2) made of polymer matrix fibrous composite material, obtained by the manufacturing method (1) defined according to any one of the preceding claims, the aerodynamic or hydrodynamic structure (2) comprising: - a hollow inner intermediate part (21A, 21B) made of polymer matrix fibrous composite material, housing at least one electronic device (22) inside its inner housing (211); - an outer aerodynamic or hydrodynamic part (25) made of polymer matrix fibrous composite material enveloping the hollow inner intermediate part (21A, 21B) and the inner surface of which matches the outer surface of the hollow inner intermediate part (21A, 21B).

20. Aerodynamic or hydrodynamic structure (2) according to the preceding claim, in which the structure has several hollow interior intermediate parts (21A, 21B) assembled to house the electronic device inside them.

21. Aerodynamic or hydrodynamic structure (2) according to any one of claims 19 to 20, in which the hollow interior intermediate part(s) (21A, 21B) have(s) a filling material (24), the filling material (24) taking up the mechanical forces with the exterior aerodynamic or hydrodynamic part (25), the filling material (24) being for example an expanding foam or a resin.

22. Aerodynamic or hydrodynamic structure (2) according to the preceding claim, in which the aerodynamic or hydrodynamic structure (2) is used in the following technical fields: maritime, aeronautics, automotive, railway, wind, space, defense.

23. Aerodynamic or hydrodynamic structure (2) according to the preceding claim, in which the at least one electronic device (22) is chosen from a thermal sensor, a strain gauge, a piezoelectric element, an optical fiber, an accelerometer and / or has an anti-vibration function.

24. Aerodynamic or hydrodynamic structure (2) according to any one of claims 19 to 23, in which the aerodynamic or hydrodynamic structure (2): - has a wing shape, and is for example an airplane wing, or a wind turbine blade, or - is a constituent element of a boat, for example a hull, a foil, a mast, a rudder of a windsurfing board, surfboard, windsurfing or boat.

25. Aerodynamic or hydrodynamic structure (2) according to any one of claims 19 to 24, in which the structural fibrous composite material with a polymer matrix is ​​a composite material composed of a matrix comprising carbon fibers and / or glass fibers.