Method for manufacturing a tubular component made of reinforced thermoplastic composite material

Abstract

The present invention relates to a method for manufacturing a reinforced cylindrical part 1000, wherein the method involves positioning a precursor assembly of a part to be manufactured using a tool 30, the precursor assembly being made of a pre-impregnated thermoplastic fibrous material and comprising (i) a segmented cylinder and (ii) reinforcing elements present on the inner surface of the cylinder. The vacuum forming tool comprises an inner portion 32 lined with a vacuum bag 34, facing the inner surface of the cylinder and the reinforcing elements on which the precursor assembly is positioned, and a cylindrical outer forming portion 60 facing the outer surface S2 of the cylinder, and the method comprises conforming the assembly on the outer forming portion and forming the part by co-consolidating the reinforcing elements on the inner surface of the cylinder by vacuum drawing within the vacuum forming tool, in order to obtain a composite material part to which the reinforcing elements are to be joined.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a component made of a thermoplastic matrix composite material with reinforcing elements joined by co-compaction. The present invention is particularly interested in the manufacture of a cylindrical component called a shell, which is intended to equip a space launcher, but is not limited to this application.

Background Art

[0002] Composite materials offer mass savings compared to metallic materials, which is of particular interest in the aerospace and aviation fields with regard to performance improvement.

[0003] In known techniques for providing a component made of a thermoplastic composite material having a cylindrical shape with reinforcing elements, completely satisfactory results are not obtained. Such components can, among other possible uses, especially form the shell between the stages of a space launcher, which generally receive particularly high mechanical forces and where the use of reinforcing elements is particularly important.

[0004] Reinforcing materials made of thermoplastic composite materials can be joined, at a minimum, by a process in which the joining zone is heated to melt the resin present and then the assembly is placed by cooling. However, in the specific case of components and reinforcing elements each having a cylindrical shape, the proper bonding of these elements is very demanding with respect to the shape tolerances of the components that must come into contact, and these tolerances can be difficult to obtain in the case of a double-curved shape. If the manufacture of large components is desired, the complexity of the method can be further increased. Known techniques thus lead to play between the shell and the reinforcing elements, resulting in local bonding defects that significantly reduce the performance of the component or even render it unacceptable for manufacture.

[0005] In addition to the challenge of managing air gaps, there are design and tooling cost challenges for performing this joining. The complex shapes used and the desire to place reinforcing elements on the inner surface of the shell make it difficult, especially to maintain the geometric shape of the part despite the melting of the thermoplastic and to disassemble it at the end of the process. Patent Document 1 (U.S. Patent Application Publication 2020 / 298500) discloses a method and system for co-consolidating parts made of thermoplastic composite materials. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] U.S. Patent Application Publication No. 2020 / 298500 [Overview of the project] [Problems that the invention aims to solve]

[0007] Therefore, it is desirable to have a method for manufacturing a shell made of a reinforced composite material having a tubular shape that addresses all or some of the aforementioned drawbacks. [Means for solving the problem]

[0008] This disclosure relates to a method for manufacturing a tubular component made of a reinforced thermoplastic composite material, wherein the method is: Positioning a precursor assembly of a part to be manufactured in a vacuum forming tool, wherein the precursor assembly is made of a pre-impregnated thermoplastic fibrous material and comprises (i) a segmented cylinder formed by several panels arranged juxtaposed around the axis of the cylinder, and (ii) reinforcing elements assembled on each of the several panels and present on the inner surface of the cylinder, The vacuum forming tool comprises an inner part lined with a vacuum bag, facing the inner surface and reinforcing elements of the cylinder to which the assembly is positioned, and a cylindrical outer forming part facing the outer surface of the cylinder. The method comprises conformation of an assembly on an external molded part and formation of a part by co-consolidation of reinforcing elements and a cylinder. The formation of the aforementioned part is The process involves heating the precursor assembly, during which the vacuum bag applies pressure to press the reinforcing elements against the inner surface of the cylinder, thereby pressing the precursor assembly against the outer molding section and shaping it by drawing vacuum within the vacuum forming tool, while simultaneously melting or softening the thermoplastic resin present in the precursor assembly. The present invention relates to a method comprising cooling the precursor assembly after heating, during which time the temperature is lowered to set the shape of the thus produced assembly and to obtain a composite material component to which the reinforcing element is to be fixed.

[0009] Positioning of reinforcing elements on each panel forming the cylinder section is easier compared to an assembly on a complete shell. A shaping stage, which involves pressing the elements by vacuum in conjunction with a rise in temperature to fluidize these elements, ensures proper bonding of the reinforcing elements on the cylinder, and consequently, good mechanical strength of the joint connections, as well as robust bonding between adjacent panels. The composite material components are obtained by a so-called co-consolidation operation of the panels and reinforcing elements, where the interpenetration of polymer chains generated during heating on both sides of the joint interface creates the joint after cooling.

[0010] Furthermore, external positioning of the molded portion facilitates disassembly from the internal molded surface. The internal portion in this invention has only a positioning function and no molding function, and therefore has a much simpler design and is easier to disassemble. Moreover, the external molded portion has a relatively simple design compared to the internal molded surface, which must take into account the shape complexity generated by reinforcing elements and does not interfere with these elements located on the inner surface of the cylinder.

[0011] In one embodiment, the segmented cylinder is formed by several panels juxtaposed around the axis of the cylinder, overlapping between several adjacent panels.

[0012] These characteristics allow for direct joining without the need for a third mechanical interface element, further simplifying the structure. However, this does not exceed the scope of the present invention if the panels are juxtaposed edge-to-edge with additional mechanical interface elements, such as splices, to connect each pair of adjacent panels.

[0013] In particular, adjacent panels may be thinner in their overlapping zones in the direction of their edges.

[0014] These characteristics help further minimize misalignment and stress concentration in the resulting parts.

[0015] In one exemplary embodiment, each panel has a plurality of circumferential frame segments that extend beyond the panel to form an extension, which is assembled together with the frame segments of the adjacent panel outside the joint zone between the two panels.

[0016] The assemblies between multiple frame sections increase the flexibility of this zone and thus introduce a desirable rigidity to offset the outside of the joint zone, facilitating the joining of panels during co-consolidation. Furthermore, the assemblies between frame sections help to correctly position the panels to form a cylinder.

[0017] In exemplary embodiments, the method further comprises forming a panel that is draped in a manner separate from the internal positioning section by automatic fiber placement before positioning the precursor assembly within the molding tool.

[0018] This technology enables access to a wide variety of shapes, particularly in relation to winding, or automatically draping local excess thickness or reinforcement members. Further, since the draping tool is separated from the vacuum forming tool, the manufacturing cycle time is reduced.

[0019] In one embodiment, the panel and the reinforcement element comprise carbon fiber, glass fiber, aramid fiber, or a mixture of the above fibers.

[0020] These fiber materials are particularly suitable for applications in space launch vehicles.

Brief Description of the Drawings

[0021] [Figure 1] FIG. 1 schematically shows an example of a panel that can be used in relation to the present invention. [Figure 2] FIG. 2 schematically and partially shows a cross-section of the panel in FIG. 1 with respect to the X-axis. [Figure 2A] FIG. 2A schematically and partially shows the bevel angle of the panel in FIG. 2. [Figure 3] FIG. 3 schematically shows in perspective view the overlap of two adjacent panels according to an embodiment of the present invention. [Figure 3A] FIG. 3A schematically and partially shows the details of an example of an assembly of the frame sections between two adjacent panels. [Figure 4] FIG. 4 schematically and partially shows a modified embodiment of a segmented cylinder. [Figure 5] FIG. 5 schematically and partially shows another modified embodiment of a segmented cylinder. [Figure 6] FIG. 6 schematically and partially shows another modified embodiment of a segmented cylinder. [Figure 7] FIG. 7 schematically and partially shows another modified embodiment of a segmented cylinder. [Figure 8] FIG. 8 schematically and partially shows a precursor assembly of a part to be manufactured, positioned within a vacuum forming tool, in relation to an embodiment of the present invention. [Figure 9] Figure 9 schematically shows the heating of the assembly shown in Figure 8 under vacuum. [Figure 10] Figure 10 shows a schematic and partial view of the parts after cooling. [Modes for carrying out the invention]

[0022] The present invention will now be illustrated with reference to the drawings. The present invention exists for illustrative purposes to illustrate specific embodiments of the invention and should not be construed as limiting.

[0023] A sectorized cylinder is obtained by the juxtaposition of pre-impregnated thermoplastic fiber panels. Generally, it may comprise at least two fiber panels or even at least three. The example described here concerns a four-panel cylinder.

[0024] The panels are advantageously manufactured by automated fiber arrangement, which constitutes a known technique. Each of these panels 10 comprises a fiber-reinforced member pre-impregnated with a thermoplastic resin. The choice of reinforcement and resin depends on the intended application. For example, the fiber-reinforced member comprises carbon fiber, glass fiber, aramid fiber, or a mixture of the above fibers. For example, the resin is polyallyl ether ketone (PAEK), polyether ether ketone (PEEK), polyether ketone ketone (PEKK), polyether sulfone (PES), polyphenylene sulfide (PPS), or polyetherimide (PEI). Advantageously, the same resin is used for different panels, or otherwise, a compatible resin is used.

[0025] Panel 10 extends along the X-axis corresponding to the axis of the cylinder obtained after the panels are juxtaposed, and has a shape with a curved cross-section relative to the X-axis. Panel 10 may or may not have an elongated shape along the X-axis, depending on the geometric shape desired for the part. In the illustrated example, panel 10 defines two edges 10a and 10b intended to overlap with adjacent panels, as described below. The edges 10a and 10b extend along the X-axis and can be collinear with this axis, as illustrated. Figure 1 shows an example of a possible structure of panel 10 draped in a female tool. Those skilled in the art will recognize that panels can be alternatively draped on a male tool without exceeding the technical scope of the present invention. Since draping is not an integral part of the vacuum forming tool, draping and heating operations can be performed simultaneously, thus reducing the manufacturing cycle time.

[0026] Panel 10, in the example shown in Figure 1, comprises linear stiffeners 12 made of thermoplastic composite material. Each stiffener 12 is formed from a fibrous reinforcement impregnated with the same or otherwise compatible thermoplastic resin as the resin of panel 10. These stiffeners 12 are formed by conventional means known to those skilled in the art, for example, by manual or automated draping, draping in a mold, or stamping with a press of a flat green plate to create a dry preform, and then by injecting the resin into the mold using resin transfer molding (RTM) technology. The stiffeners 12 may have any cross-section, such as omega, T, or J, among other possible shapes. The stiffeners 12 may or may not have localized variations in shape or section (cross-section). As shown, the stiffeners 12 may be present over at least a large portion (more than 50%), or at least 80%, of the panel dimension DX measured along the X-axis.

[0027] The illustrated panel 10 is also provided with circumferential frame sections 14 made of thermoplastic composite material that constitutes reinforcing elements. Each frame section 14 is formed of a fibrous reinforcing member impregnated with the same or otherwise conforming thermoplastic resin as the panel 10 and the reinforcing members 12. With respect to the reinforcing members 12, the frame sections 14 are formed by known methods. The frame sections 14 may have any cross-section, such as Z-shaped, C-shaped, F-shaped, T-shaped, omega-shaped, or J-shaped. Each frame section may have a joggle at its end (to overlap with other frame sections to form a complete frame) or be straight (to join other frame sections via splice bars). The frame sections 14 may have variations in shape at the base plate that contacts the panel 10 (to best accommodate variations on the panel 10 side). The frame sections 14 may have notches that are traversed by the reinforcing members 12 and cooperate with these reinforcing members. These notches may have the same shape and substantially the same dimensions as the reinforcing members 12 through which they pass. The frame section 14 can be assembled to the reinforcing members 12 by interface pieces, but the omission of such pieces does not exceed the scope of the present invention.

[0028] Once the panels 10 are placed side by side, the frame sections 14 and reinforcing members 12 are assembled on the inner surface of the cylinder. Note that, in general, the panels 10 may include zones with increased thickness that form local reinforcing members.

[0029] The reinforcing members 12 and frame sections 14 are assembled on the panel 10 by techniques known to themselves, such as spot joining, stapling, or the use of attached fasteners. The purpose of this assembly is simply to position the reinforcing members 12 and frame sections 14 on the panel 10, but not to firmly fix them to the panel 10, which is achieved after co-consolidation as described below.

[0030] In the illustrated example, panel 10 also has a zone 19 located on the side of edge 10b, which extends across the entire dimension DX and lacks reinforcing elements (neither reinforcing member 12 nor frame section 14). Note that in the illustrated example, frame section 14 also protrudes from panel 10 on the opposite side of zone 19 (towards edge 10a), forming an extension 15 of frame section 14. The presence of zone 19 and the extension of frame section 14 is a result of the assumed arrangement for juxtaposing adjacent panels 10.

[0031] Figure 2 shows the variation of the thickness e10 of panel 10 along the Y-axis perpendicular to the X-axis. Panel 10 has an intermediate zone 101 of its width where the thickness e10 is substantially constant, and two lateral zones 103a and 103b located on the sides of each edge 10a, 10b, respectively, which have varying thicknesses. Zone 101 is located between zones 103a and 103b. Zone 103a connects zone 101 to edge 10a, and zone 103b connects zone 101 to edge 10b. More precisely, zones 103a and 103b become thinner in the direction of the associated edges 10a and 10b. The thickness e10 can decrease precisely in the direction of the edges 10a and 10b. The thickness e10 is minimum at the edges 10a and 10b and maximum at the intermediate zone 101. Panel 10 has bevels in cross-section at its edges 10a and 10b, and has a shape that tapers toward its edges 10a and 10b with respect to the X axis. Zones 103a and 103b together occupy at least 5%, e.g., at least 50%, of the dimension DY of panel 10. Unless otherwise specified, dimension DY corresponds to the arc length of the curve connecting edges 10a and 10b. The thickness reduction results in a thickness e10 reduction of at least 50%, e.g., at least 90%. This thickness e10 reduction consists of, for example, between 50% and 95%, or even between 90% and 95%. Figure 2A schematically shows the thickness reduction of panel 10 in the direction of edge 10b, related to the presence of a reduction in the overlapping fold PS in the direction of edge 10b. The bevel angle α corresponding to the locally measured angle on the edge 10b can, advantageously, be 1.5° or less, resulting in further improvement in force smoothing.

[0032] The juxtaposition of these panels 10 to form the segmented cylinder 100 will be described below in reference to Figures 3 to 7. The reinforcing members 12 and frame segments 14 are not shown in Figures 4 to 7.

[0033] Figure 3 shows the juxtaposition of two adjacent panels 10 around the X-axis. The two illustrated panels 10 have the same structure, and the same reference numbers are maintained with respect to what has just been described. These panels 10 partially overlap here. These panels are reduced in thickness in their overlapping zone ZR 10. That is, zone 103b of the first panel 10 is covered by zone 103a of the adjacent second panel 10. The adjacent second panel 10 overlaps the edge 10b of the first panel 10, and the first panel overlaps the edge 10a of the second panel 10. The reinforcing members 12 and frame divisions 14 of the second panel 10 cover zone 19 of the first panel 10. The extension 15 of the frame division 14 of the second panel 10 extends across zone 101 of the first panel and is positioned adjacent to the frame division 14 of the first panel at the extension. The extension 15 extends beyond the overlap zone ZR10, where it corresponds to the joining zone between these panels 10. The extension 15 is assembled with the frame section 14 of the first panel 10 by techniques known to themselves, such as overlapping, joggling, or splicing. This assembly can be performed outside of zone ZR10. Figure 3A shows an example of an assembly in which a splice bar 14a located outside of zone ZR10 connects the frame sections 14 of the first and second panels 10. The splice bar 14a may also contain a thermoplastic material to ensure its bonding to the frame section 14 during co-consolidation.

[0034] The configuration described above can be applied to each pair of adjacent panels 10 that are juxtaposed to form a partitioned cylinder. Generally, the overlapping zone between adjacent panels can occupy at least 5%, for example, at least 30%, of the perimeter of the partitioned cylinder. The wider the overlapping zone, the more the mechanical properties of the resulting part can be improved. In particular, when all the panels are assembled to form a partitioned cylinder, the combination of each frame section 14 of the panel defines multiple 360° circumferential frames.

[0035] Figures 4 to 7 show different modified embodiments of the juxtaposition of panels 10 to form a segmented cylinder 100. The cylinder 100 is an X-axis cylinder having panels juxtaposed around this axis. The X-axis corresponds to the rotation axis of the cylinder.

[0036] In the modified embodiment shown in Figure 4, the cylinder 100 is formed by stacking all the panels 10 in a tile-like manner. That is, each of these panels has a first edge 10b that overlaps (above) with a first adjacent panel, and a second edge 10a that overlaps (below) with a second adjacent panel opposite to the first adjacent panel and opposite to the first adjacent panel. It is noteworthy that, in particular, the thickness of adjacent panels 10 decreases in the direction of the edges 10a and 10b of the panels 10 across the overlapping zone ZR10 of the panels 10.

[0037] In the modified embodiment shown in Figure 5, the panels are stacked in a tile-like fashion, except for panel 10 in the lower right of the figure, which overlaps with two adjacent panels.

[0038] The modified embodiments shown in Figures 6 and 7 illustrate cases where there is no overlap in the scope of the present invention.

[0039] The case where the beveled panels 10 have reduced thickness over their overlapping zones was described immediately. Note that the invention does not extend to cases where the panels have straight sides or joggles (which allow them to be assembled by overlapping).

[0040] The positioning in a vacuum forming tool is described below. Here, the possible kinematics for the assembly of the vacuum forming tool 30 and the positioning of the precursor assembly are described in detail with reference to Figure 8. In Figure 8, as with Figures 9 and 10, the relative thicknesses and spacings between different elements are not strictly observed for readability reasons.

[0041] First, the vacuum bag 34 is placed on the positioning section 32. The positioning section 32 is much simpler in design than the molding surface because it is simply used to position the element. Therefore, it can be disassembled more easily. The positioning section 32 is supported by a shaft 36 that extends along the X-axis corresponding to the X-axis of the panel 10 and cylinder 100, as previously described. The positioning section 32 may have a ventilation structure, for example, a lattice structure, or it may have a plurality of retractable positioning elements fixed to the shaft. The positioning section 32 may generally have the shape of the part to be obtained, as shown in the figure. The bag 34 covers the positioning section 32. The bag 34 may be made of an elastomer material, may be optionally reinforced, and constitutes a known element itself.

[0042] Next, the positioning ring 40 is positioned on the ends 361, 363 of the shaft 36, which defines a cylindrical positioning surface 42 intended to guide the external molded portion 60 during positioning.

[0043] Next, the panel 10 is positioned and juxtaposed in the manner described above to form a cylinder 100, which is a precursor to the part to be obtained. The cylinder 100 is positioned around the positioning section 32 (and bag 34). In the illustrated example, each panel 10 carries a plurality of frame sections 14 and a plurality of reinforcing members 12. The positioning section 32 can define the housing, for example, in the form of a cavity opening onto the surface of the positioning section 32 where the reinforcing elements 12, 14 are placed. The reinforcing elements 12, 14 may abut against the wall defining the cavity or against positioning elements present within the cavity to assist in their placement within the tool 30.

[0044] The cylinder 100 divides the internal volume V of the resulting part. The cylinder 100 is made of a pre-impregnated thermoplastic fiber material. Reinforcing elements 12 and 14 are assembled to the inner surface S1 of the cylinder 100. In the illustrated example, these reinforcing elements 12 supported by the cylinder 100 may be arranged at regular intervals along the circumferential direction centered on the X-axis. Similarly, the frame sections 14 supported by the cylinder 100 may be arranged at regular intervals along the X-axis. However, even if these intervals are not regular, it does not exceed the scope of the invention, and the positioning of the reinforcing elements is adjusted according to the parts and the forces that the parts experience during operation.

[0045] In the illustrated example, cylinder 100 has a diameter larger than its dimension along the X-axis. However, even when applying the present invention to the formation of a part having an elongated shape along the X-axis, for example, a part having a length of at least 10 meters, it does not exceed the scope of the present invention.

[0046] Next, the external molding section 60 is positioned, which is the shape of the part to be obtained and surrounds the cylinder 100. The cylinder 100 is located inside the external molding section 60. The external molding section 60 is positioned around the cylinder 100. As shown in the figure, the external molding section 60 extends from one ring 40 to the other ring 40. The external molding section 60 faces the positioning surface 42. The inner surface S1 of the cylinder 100 is located on the side of the bag 34 (and demarcates the internal volume section V), and the outer surface S2 of the cylinder 100 is located on the side of the external molding section 60. In the illustrated example, the shaft 36 is oriented vertically, as is the tool 30, but those skilled in the art will recognize that the present invention can be applied to a tool 30 that extends horizontally. In this case, especially when the manufacture of a part of considerable length is envisioned, it is useful to provide reinforcing material on the side of the molding section opposite to the assembly in order to maintain its shape.

[0047] Next, a seal 52 is created between the bag 34 and the external molded part 60.

[0048] The precursor assembly is thus positioned within the vacuum forming tool 30, and the part is formed by co-consolidation. In particular, the cylinder 100 is interposed between the bag 34 and the forming section 60. The positioning section 32 is located inside the precursor assembly, that is, inside the internal volume V of the resulting part. The external forming section 60 is located outside this internal volume V and forms the external part of the assembly for the purpose of forming the part.

[0049] In the illustrated example, the panels 10 are arranged side by side around the X-axis with overlaps between adjacent panels. Adjacent panels 10 may be in contact on their overlap zone ZR10. The reinforcing members 12 and frame sections 14 may be in contact with the inner surfaces of the panels 10 and, consequently, the cylinder 100.

[0050] The bag 34 presses the reinforcing elements 12 and 14 onto the inner surface S1 of the cylinder 100, creating a vacuum within the tool 30 so that the assembly conforms to the desired shape relative to the outer molded part 60. In particular, the vacuum causes the panels 10 to contact their overlapping zone ZR10, and also applies pressure to the reinforcing members 12 and frame sections 14 pressed against the inner surface S1. Pressure is also applied to any third assembly element useful for connecting the frame sections 14 of adjacent panels 10, pressing the assemblies to be connected against the surface S1.

[0051] Next, heating is performed while maintaining vacuum, which leads to the melting or softening of the present thermoplastic resin(s). Fluidization of the resin(s) promotes the conformation of the elements to be joined and causes interpenetration of polymer chains at the interfaces between these elements. Thus, during heating, in each pair of adjacent panels, the resin of the first panel penetrates into the second adjacent panel, the resin of the second panel penetrates into the first panel, the resin(s) of the reinforcing elements penetrate into the panel in which these elements are assembled, the resin of the relevant panel penetrates into these reinforcing elements, and the resin of the first pair of frame sections 14 penetrates into the second pair of frame sections 14 adjacent to this first pair.

[0052] Heating can be carried out in a heating chamber such as an oven or autoclave. An autoclave provides additional pressure beyond the vacuum. In a modified embodiment or in combination, a molding tool equipped with a heating element (not shown) can be used to perform this heating. The temperature imposed during heating depends on the resin used and can be, for example, 300°C or higher, and may consist of, for example, 300°C to 400°C.

[0053] After heating, cooling is performed to arrange the structure (particularly the thermoplastic resin present) and obtain part 1000 (Figure 10). Generally, vacuum can be maintained during this cooling. Cooling allows bonding to be achieved between different elements of the part due to the interpenetration of polymer chains of the resin (or more) previously performed during heating. Part 1000 is cylindrical and tubular, forming a reinforced shell. All components of the structure are co-consolidated to form an integral structure with the assembly. In particular, these panels 10 are joined to each other by co-consolidation to form a shell, the reinforcing members 12 and frame sections 14 are joined to each other by co-consolidation on the inner surface of part 1000, and the frame sections 14 are joined to each other by co-consolidation (e.g., by overlapping or splicing).

[0054] By using a tool 30 made of a composite material, the phenomenon of expansion difference between the tool 30 and the part 1000 can be reduced. In a modified embodiment, the tool 30 may be made of metal, such as Invar or steel. In the case of steel, it may be advantageous to minimize stress during cooling by providing a partial opening in the external forming portion 60.

[0055] Next, the tool 30 is disassembled, which is facilitated by the outward positioning of the resulting part 1000 of the molding section 60 and the simplified design of the inner section 32.

[0056] The resulting component 1000 can be integrated into a space launcher, for example, as a shell between stages or between tanks, or it can form a tank after the bottom element is attached. However, the field of the present invention is not limited to components for integration into aerospace launchers, and the component can find applications in the aerospace field, or more generally, any application requiring a reinforcing shell, in modified embodiments.

[0057] The expression "comprised between ... and ..." should be understood as having a boundary.

Claims

1. A method for manufacturing a cylindrical part (1000) made of a reinforced thermoplastic composite material, wherein the method is: Positioning a precursor assembly of a part to be manufactured in a vacuum forming tool (30), wherein the precursor assembly is made of a thermoplastic pre-impregnated fibrous material and comprises (i) a segmented cylinder (100) formed by several panels (10) arranged juxtaposed around the axis (X) of the cylinder, and (ii) reinforcing elements (12, 14) assembled on each of the several panels and present on the inner surface (S1) of the cylinder, The vacuum forming tool comprises an inner portion (32) lined with a vacuum bag (34) that faces the inner surface and reinforcing element of the cylinder on which the precursor assembly is positioned, and a cylindrical outer forming portion (60) that faces the outer surface (S2) of the cylinder. The method comprises conforming the assembly on the external molded portion and forming a component by co-consolidating the reinforcing element and the cylinder. The formation of the aforementioned part is The process involves heating the precursor assembly, during which the vacuum bag applies pressure to press the reinforcing elements against the inner surface of the cylinder, thereby pressing the precursor assembly against the outer molding section and shaping it by drawing vacuum within the vacuum forming tool, while simultaneously melting or softening the thermoplastic resin present in the precursor assembly. A method comprising cooling the precursor assembly after heating, during which time the temperature is lowered to set the shape of the thus produced assembly and obtain a composite material component to which the reinforcing element is to be fixed.

2. The method according to claim 1, wherein the segmented cylinder (100) is formed by several panels (10) that are arranged side by side around a cylinder axis (X) and overlapping between several adjacent panels.

3. The method according to claim 2, wherein several adjacent panels (10) have thinner portions on their overlapping zone (ZR10) in the direction of their edges (10a, 10b).

4. The method according to any one of claims 1 to 3, wherein each panel (10) comprises a plurality of circumferential frame sections (14) that extend beyond the panel and form an extended portion (15), and the extended portion is joined to the plurality of circumferential frame sections of an adjacent panel outside a joining zone (ZR10) between the two panels.

5. The method according to any one of claims 1 to 4, further comprising the following: before positioning the precursor assembly in the vacuum forming tool (30), the several panels (10) are formed by automatic fiber arrangement, and the several panels are draped in a shape different from the inner portion being positioned.

6. The method according to any one of claims 1 to 5, wherein some of the panels (10) and reinforcing elements (12, 14) are made of carbon fiber, glass fiber, aramid fiber, or a mixture of the carbon fiber, glass fiber, or aramid fiber.

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