Method and device for manufacturing structural elements of composite material with Z-shaped profiles

Abstract

A method is described for manufacturing a structural element (2) of composite material, extending along a straight or curved longitudinal direction (D), having a Z-shaped cross section, and comprising, in its final configuration, a central web (2a) and two flanges (2b, 2c) extending from both end portions of the web (2a) in opposite directions at a given final angle, the method comprising the steps of placing a plurality of layers (3) of composite material in a forming section (4) of a mold, at least a portion of the web (2a) being disposed in its final configuration, and a first flange (2b) being disposed in its final configuration at a final angle relative to the portion of the web (2a) disposed in its final configuration; The method includes the steps of stacking multiple layers (3) on a forming portion (4) so ​​that the second flange (2c) is, in its initial configuration, positioned at a larger initial angle relative to a portion of the web (2a) at which it will be positioned in its final configuration, the larger initial angle being different from the final angle; moving a movable portion (6) of the forming mold, which is movable from a stationary position to a bending position, relative to a fixed portion (5) of the forming mold; and displacing the second flange (2c) from the initial configuration to a final configuration at the final angle relative to a portion of the web (2a) at which it will be positioned in its final configuration, wherein the displacing step (d) is carried out using the moving step (c).

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This patent application claims priority from Italian Patent Application No. 102020000028046, filed November 23, 2020, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention relates to a method for manufacturing structural elements of composite material which extend along a straight or curved longitudinal direction and which have a Z-shaped cross section in relation to that longitudinal direction, and in particular to a method for manufacturing structural elements of composite material which are used in the aeronautical sector and which form part of the structure of an aircraft, such as beams, stringers and spars of an airplane fuselage, to which the following description explicitly refers without loss of generality.

[0003] The present invention relates to a device for manufacturing structural elements of composite material which extend along a straight or curved longitudinal direction and have a Z-shaped cross section in relation to the longitudinal direction, and in particular to a device for manufacturing structural elements of composite material which are used in the aeronautical sector and which form part of the structure of an aircraft, such as beams, stringers and spars of an airplane fuselage, to which the following description explicitly refers without loss of generality. [Background technology]

[0004] Structural elements such as airframes and parts thereof made of composite materials and used in the aviation field are known, the use of said materials being dictated by the need to reduce the overall weight of the aircraft and to eliminate or minimize corrosion problems in the flight structures.

[0005] According to the state of the art, there are flight structural elements that must be manufactured from light alloys, i.e. metallic materials, before being applied to the airframe.

[0006] The use of said metal elements and their assembly in contact with structures in composite materials brings about galvanic problems associated with the risks associated with corrosion of metals and the need for increased levels of inspection, which leads to an overall increase in costs for the producers of these components and therefore for airlines.

[0007] This has created a need for these structural elements to be made from composite materials as well.

[0008] The use of composite materials can reduce the overall weight of the aircraft while at the same time providing a very strong structure.

[0009] To fabricate the above structural elements, multiple layers of uncured or pre-cured composite material are placed in an appropriately shaped forming tool, depending on the shape to be imparted to the structural element.

[0010] Composite materials are typically fibrous materials, with each layer typically consisting of a thermosetting (resin) matrix prepreg reinforced with various types of fibers, such as carbon fiber, aramid fiber, or glass fiber.

[0011] The resulting layers are then laminated together in a forming tool.

[0012] After lamination, the forming process is carried out in a forming mold, usually with the aid of a vacuum, in which the layers are compressed and the desired shape (e.g., T-shaped, Z-shaped, C-shaped, Ω-shaped profile, etc.) is given to the structural element.

[0013] The assembly so formed is then subjected to a curing process in a curing mold by applying high pressure and temperature to harden the composite material and compress the aforementioned layers together.

[0014] Structural elements of composite material, such as beams, stringers, girders and the like, are known which extend along a straight or curved longitudinal axis and have a Z-shaped cross section with respect to the longitudinal direction (i.e. have a Z-shaped profile), having a central portion which defines a web of the structural element, and two end portions which are located on either side of the web and define two respective wings or flanges at right angles to the web and which extend in opposite directions so as to precisely define the Z-shaped profile.

[0015] There is a felt need in the field to fabricate composite structural elements in Z-profiles using operations that can be easily automated, preferably using automatic operations, without the manual assistance of an operator. Summary of the Invention [Problem to be solved by the invention]

[0016] The object of the present invention is to provide a method for manufacturing composite structural elements extending along a straight or curved longitudinal direction and having a Z-shaped cross section with respect to the longitudinal direction, which makes it possible to meet in a simple and economical manner the aforementioned needs associated with composite structural elements with Z-shaped cross sections of known types. [Means for solving the problem]

[0017] According to the invention, this object is achieved by a method for manufacturing a structural element of composite material with a Z-shaped cross section, as claimed in claim 1.

[0018] A further object of the present invention is to realize a device for the manufacture of composite structural elements extending along a straight or curved longitudinal direction and having a Z-shaped cross section with respect to the longitudinal direction, which makes it possible to meet in a simple and economical manner the aforementioned needs associated with composite structural elements with Z-shaped cross sections of the known type.

[0019] According to the invention, this object is achieved by a device for the production of structural elements of composite material with a Z-shaped cross section, as claimed in claim 8.

[0020] For a better understanding of the invention, some preferred, non-limiting embodiments are described below, purely by way of example, with the aid of the accompanying drawings, in which: [Brief explanation of the drawings]

[0021] [Figure 1] FIG. 1 is a perspective view of a portion of a device for the manufacture of structural elements of composite material with Z-shaped profiles, with parts removed for clarity. [Figure 2] FIG. 2 is a perspective view of a structural element of composite material with a Z-shaped profile obtained with the device in FIG. 1. [Figure 3] 2 is a schematic top view, on an enlarged scale and with parts removed for clarity, of a detail of the device of FIG. 1 during given operating conditions; [Figure 4A] 2A-2C are schematic, partially cross-sectional views of the device of FIG. 1 according to a first embodiment of the invention during three subsequent operating conditions, with parts removed for clarity; [Figure 4B] 2A-2C are schematic, partially cross-sectional views of the device of FIG. 1 according to a first embodiment of the invention during three subsequent operating conditions, with parts removed for clarity; [Figure 4C] 2A-2C are schematic, partially cross-sectional views of the device of FIG. 1 according to a first embodiment of the invention during three subsequent operating conditions, with parts removed for clarity; [Figure 5A] 2A-2C are schematic, partially cross-sectional views of the device of FIG. 1 according to a second embodiment of the invention during three subsequent operating conditions, with parts removed for clarity; [Figure 5B]2A-2C are schematic, partially cross-sectional views of the device of FIG. 1 according to a second embodiment of the invention during three subsequent operating conditions, with parts removed for clarity; [Figure 5C] 2A-2C are schematic, partially cross-sectional views of the device of FIG. 1 according to a second embodiment of the invention during three subsequent operating conditions, with parts removed for clarity; [Figure 6A] 2A-2C are partial cross-sectional views, with parts removed for clarity, illustrating schematically the device of FIG. 1 according to a third embodiment of the invention between two subsequent operating conditions; [Figure 6B] 2A-2C are partial cross-sectional views, with parts removed for clarity, illustrating schematically the device of FIG. 1 according to a third embodiment of the invention between two subsequent operating conditions; [Figure 7A] 1 according to a fourth embodiment, with parts removed for clarity, shown for illustrative purposes only and not within the scope of protection of the claimed invention, but useful for understanding the claimed invention; [Figure 7B] 1 according to a fourth embodiment, with parts removed for clarity, shown for illustrative purposes only and not within the scope of protection of the claimed invention, but useful for understanding the claimed invention; [Figure 7C] 1 according to a fourth embodiment, with parts removed for clarity, shown for illustrative purposes only and not within the scope of protection of the claimed invention, but useful for understanding the claimed invention; DETAILED DESCRIPTION OF THE INVENTION

[0022] With reference to the accompanying drawings, the number 1 designates a device for the manufacture of a structural element 2 of composite material extending along a curved longitudinal direction D and having a Z-shaped cross section relative to the longitudinal direction.

[0023] In particular, the structural element 2 is a multi-layer element having a Z-shaped profile and used in the aeronautical field and forming part of the structure of an aircraft (not shown), such as a beam, stringer or spar of an airplane fuselage, to which the present description refers without loss of generality.

[0024] In one embodiment not shown, the structural element 2 may extend along a straight longitudinal direction.

[0025] The structural element 2 is advantageously used to strengthen the aircraft fuselage in order to reduce the overall weight of the aircraft fuselage and at the same time obtain a strong structure.

[0026] In the example described, the structural element 2 has a significantly greater extension along the longitudinal direction D than in the other two directions perpendicular to this longitudinal direction D.

[0027] As can be seen in Figure 2, the structural element 2 has a cross-section with a Z-shaped profile in the longitudinal direction D, and in its final configuration, which is shown in Figures 4C, 5C, 6B and 7C in addition to Figure 2, it comprises a central web 2a and two wings or flanges 2b, 2c extending perpendicularly in opposite directions from both end portions of the web 2a.

[0028] The longitudinal direction D has a non-zero radius of curvature R.

[0029] In an embodiment not shown, the flanges 2b, 2c may extend from the web 2a at a given final angle other than 90°, such as, for example but not exclusively, 30°, 45°, 60°, 80°, 85°.

[0030] In particular, the final angles of the flanges 2b, 2c may differ from each other.

[0031] The structural element 2 described and illustrated here is made starting from several layers 3 of composite material, each layer being constituted by a prepreg with a polymer matrix, for example in a thermosetting resin, preferably reinforced by fibers which may have different properties, for example carbon fibers, aramid fibers and / or glass fibers.

[0032] Alternatively, the structural element 2 may be made starting from a prepreg, preferably with a thermoplastic resin matrix, preferably reinforced with fibers of the type indicated above.

[0033] Preferably, the composite material is defined by a cured or pre-cured material.

[0034] In view of the above, each layer 3 is defined by a composite material comprising fibers dispersed in a thermoplastic polymer matrix.

[0035] FIG. 2 shows the structural element 2 in its final configuration obtained with the device 1.

[0036] The device 1 comprises a mold carrying a shaped part 4 .

[0037] Referring to Figures 1, 3 and 4A-4C, the structural element 2 is obtained by placing the aforementioned layers 3 of composite material into a mold, in particular into a molding portion 4 of the mold, preferably using automated movement, such as using a programmable robot 20, so as to be controlled in an automated manner.

[0038] In particular, the robot 20 is configured to place, in an automated manner, each layer of fiber composite material onto the mold section, advantageously with a predetermined orientation that differs from layer to layer.

[0039] More precisely, as can be seen in FIG. 3, the robot 20, in use, drives the forming part 4 according to a predetermined sequence, namely: - arranging the layer 3a of fibrous material according to an orientation of 0° along the (curvilinear) longitudinal direction D, i.e. an orientation parallel to the longitudinal direction D, - arranging the layer 3b of fibrous material according to an orientation of 45° to the longitudinal direction D, - arranging the layer 3c of fibrous material according to an orientation at −45° to the longitudinal direction D, i.e. according to an orientation perpendicular to the orientation of the layer 3b, - A layer 3d of fibrous material is arranged according to an orientation of 90° to the longitudinal direction D.

[0040] In an alternative embodiment not shown, the placement of layer 3 may be performed manually by an operator.

[0041] In the example described, thanks to the use of the robot 20 for laying the composite fibre layers 3 in a predetermined orientation, it is possible to obtain a so-called "steering" of these fibres, which is particularly advantageous when the longitudinal direction D of the structural element 2 has a non-zero radius of curvature R, i.e. is curved. In particular, the fibres of the layer 3a at 0° are directly laid up in the moulding section 4 into respective strips, which each define a continuous "single piece" with a non-zero radius of curvature R.

[0042] In this way, the fibers can be arranged directly by bending them in a continuous manner, rather than in a "loose" and discontinuous manner, which leads to a considerable improvement in terms of the mechanical properties of the structural element 2, since there are no joints between the fibers.

[0043] Advantageously, the structural element 2 comprises a plurality of layers 3 including layers 3a, 3b, 3c, 3d superimposed on one another according to a predetermined pattern.

[0044] Once the layer 3 is placed in the molding section 4, for example using the robot described above, it is placed in the molding section 4 as follows (FIG. 4A): - at least a portion of the web 2a is arranged in its final configuration, the first flange 2b is arranged in its final configuration, i.e. at a given final angle, preferably perpendicular, relative to the web 2a, more precisely relative to the position of the web 2a where it is arranged in its final configuration; - so that the second flange 2c is, in its initial configuration, arranged relative to the web 2a, or more precisely to the part of the web 2a where it will be arranged in its final configuration, at a larger initial angle different from the relative final angle, preferably different from 90° (not a right angle), They are laminated together in an automated manner.

[0045] In the example shown in Figure 4A, the web 2a is generally arranged in its final configuration and the second flange 2c is arranged at 180° to the web 2a, or more precisely, the second flange 2c defines the extension of the web 2a.

[0046] In other words, the layers 3 are initially placed in the forming section 4 so that the laminate forms an L-shaped profile, the short side of which is defined by the first flange 2b and the long side of which is defined by the web 2a and the second flange 2c.

[0047] The device 1 , specifically the forming mould, comprises a fixed part 5 and a movable part 6 that is movable relative to the fixed part 5 .

[0048] The fixed part 5 and the movable part 6 together define the shaped part 4, more precisely the shaped part 4 is defined in part by the outer shaped surface of the fixed part 5 and in part by the outer shaped surface of the movable part 6.

[0049] 4A and 4B, in use, the layers 3 are stacked such that the second flange 2c is located on the movable portion 6. In FIG.

[0050] In other words, the portion of the layer 3 constituting the second flange 2c is arranged to be supported by the aforementioned outer forming surface of the movable portion 6.

[0051] The device 1 comprises actuator means 7 configured to drive the movement of the movable part 6 relative to the fixed part 5 from a rest position (Figures 4A and 4B) to a bent position (Figure 4C), preferably in an automated manner.

[0052] In particular, the device 1 comprises a control unit (not shown) configured to drive the movement of the movable portion 6 from the rest position to the bending position in an automated manner.

[0053] Advantageously, the movable part 6 is configured to be moved from a rest position to a bending position in order to move the second flange 2c from an initial configuration to a final configuration, i.e. a configuration that defines the aforementioned final angle with the web 2a, which is preferably a right angle (90°), and in particular to bend it.

[0054] More precisely, the movable portion 6 is adapted to press the second flange 2c so as to bend it from an initial configuration to a final configuration in an automated manner.

[0055] In this way, a composite structural element 2 with a Z-shaped profile (Fig. 4c) is obtained in a simple, fast and economical manner, preferably in a totally automated manner with automatic movement of the movable part 6 from a rest position to a bending position without manual intervention of the operator.

[0056] According to this preferred embodiment, the movable part 6 is adapted to translate linearly relative to the fixed part 5 .

[0057] For this purpose, the actuator means 7 a piston 8, such as a hydrodynamic piston (pneumatic, hydraulic or hydraulic) fixed to one end of the movable part 6 opposite the relative external forming surface; a guide and slide system 10 configured to guide the movable part 6 to define a linear translation of the movable part 6; Equipped with.

[0058] Alternatively, the actuator means 7 may comprise an electrodynamic actuator, such as a linear motor (not shown) defined by a guide slide system 10 .

[0059] In use, the piston 8 is actuatable to drive a linear translational movement, guided by the guiding and sliding system 10, of the movable part 6 from a rest position to a bending position.

[0060] Advantageously, the operation of the piston 8 is automatically controlled by a control unit.

[0061] Alternatively, the piston 8 may be manually driven by an operator.

[0062] Preferably, the device 1 comprises infrared means, such as at least one infrared lamp, known per se and not described or shown in detail, configured to emit infrared radiation towards the layers 3 during the lamination operation, and in particular during the subsequent forming operation, so as to make the resin with which the material is pre-impregnated somewhat less viscous and to cause the layers 3 to slide together. In this way, wrinkles are avoided during forming, in particular during bending of the second flange 2c.

[0063] In one embodiment, the infrared means is carried by the robot 20 .

[0064] Conveniently, the device 1 further comprises an abutment 11 which can be displaced between a rest position (not shown) and a compression position (Figure 4B) in which it abuts against the plurality of layers 3, so that the web 2a is interposed between the abutment 11 and the forming part 4 (i.e. the forming mold).

[0065] In particular, the abutment body 11 is configured to be placed against the web 2a.

[0066] In use, the aforementioned control unit drives the displacement of the abutment 11 to a compression position in order to compress at least the web 2a.

[0067] Advantageously, the displacement (bending) of the second flange 2c is performed by means of the movable part 6 until the second flange 2c abuts against the abutment body 11, as can be seen in Figure 4b.

[0068] In this way, a more effective bending of the second flange 2c can be achieved, ensuring a correct final angle of the second flange 2c relative to the web 2a, in particular the aforementioned angle of 90°.

[0069] Preferably, once the lamination and formation of the structural element 2 has been completed according to the methods described above, the structural element 2 is placed, during use, in a curing or co-curing device (known per se and not shown) according to known methods and not described in detail, in order to carry out at least one curing or co-curing cycle.

[0070] More specifically, the structural element 2 is inserted into a vacuum bag and placed in a curing or co-curing device (typically an autoclave) to expose it to a specific pressure and a specific temperature as known in the industry.

[0071] With the above in mind, the polymerization cycle of structural element 2 is carried out.

[0072] If the matrix resin is of the thermoplastic type, one or more "toughening" cycles are carried out according to known methods not described in detail.

[0073] With reference to Figures 5A, 5B and 5C, the reference numeral 1' designates a device for the manufacture of a structural element 2 of composite material with a Z-shaped cross section (profile) made according to a second embodiment of the invention.

[0074] Because device 1' is structurally and functionally similar to device 1, it will be described below only in those aspects that distinguish device 1' from device 1, and where possible, corresponding parts and components will be designated with the same reference numerals.

[0075] In particular, device 1' differs from device 1 in that the movable part 6 is hingedly connected to the fixed part 5 using hinge 12, and that the movable part 6 comprises actuator means 7' configured to move the movable part 6 from a rest position to a bent position relative to the fixed part 5 in a pivotal manner about hinge 12.

[0076] In the example described, the actuator means 7' comprises a piston 8', such as a hydrodynamic piston (pneumatic, hydraulic or hydraulic) fixed to one end of the movable part 6 opposite the relative external forming surface.

[0077] The piston 8' is arranged to be driven in an automated manner by a control unit.

[0078] Alternatively, the piston 8' may be manually driven by an operator.

[0079] In view of what has been described above, the movable part 6 is adapted to be moved, preferably in an automated manner, between a rest position and a bent position by means of a piston 8' and to perform pivoted rotation about the hinge 12.

[0080] In this way, since the configuration of device 1' does not require a guide slide system 10, it is possible to obtain bending of second flange 2c to its final configuration in a more efficient manner using a simpler structure than when device 1 is used.

[0081] With reference to Figures 6A and 6B, the reference number 1'' designates a device for the manufacture of a structural element 2 of composite material with a Z-shaped cross section (profile) made according to a third embodiment of the invention.

[0082] Because device 1'' is structurally and functionally similar to device 1', it will be described below only in those aspects that distinguish device 1'' from device 1', and where possible, corresponding parts and components will be designated with the same reference numerals.

[0083] In particular, device 1'' differs from device 1' in that it comprises elastic return means 7'' which define the aforementioned actuator means and are interposed between fixed part 5 and movable part 6 and are configured to be released from a deformed position to a non-deformed position, preferably in an automated manner, to drive movement of movable part 6 from a rest position to a bent position, preferably in an automated manner.

[0084] In detail, the elastic return means 7'' comprises a spring 8'', preferably a helical spring, fixed at a first end to the end of the movable part 6 opposite the relative external forming surface and at a second end to the fixed part 5.

[0085] The spring 8 ″ is compressed in the deformed position to keep the movable portion 6 in a stationary position during the lamination of the layer 3 onto the molded part 4 .

[0086] In use, the spring 8'' can be released from a compressed, deformed position (Figure 6A) to an extended, undeformed position (Figure 6b), preferably in an automated manner on command of a control unit, so as to displace the movable portion 6 from a rest position to a bent position and thus determine bending of the second flange 2c.

[0087] Alternatively, the spring 8'' may be manually actuated by an operator.

[0088] This configuration makes it possible to obtain a system for driving the movement of the movable part 6 that is even simpler than the configuration of the previously described embodiment.

[0089] Advantageously, device 1'' differs from device 1' in that, in its initial rest position, movable part 6 is positioned at an angle other than 180° relative to fixed part 5, in particular at an angle greater than 90° and less than 180°.

[0090] As shown in FIG. 6A, this causes layer 3 to be laminated to shaped portion 4 so that second flange 2c, in its initial configuration, is positioned at an angle other than 180° relative to web 2a, specifically, at an angle greater than 90° and less than 180° relative to web 2a.

[0091] This particular arrangement means that the bending of the second flange 2c is already "started" or pre-executed in a way during the lay-up using the robot 20. This has the added advantage that during the actual bending of the second flange 2c using the movable part 6, the second flange 2c will cut into the bend and adapt to the bend more easily.

[0092] Furthermore, thanks to this adaptation, the mould forming part 4 is particularly suitable for automatic lamination, ie carried out in an automated manner using a robot 20 .

[0093] With reference to Figures 7A, 7B and 7C, the reference numeral 1''' designates a device for the manufacture of a structural element 2 of composite material with a Z-shaped cross section (profile) made according to a fourth embodiment, which is given by way of example only and which does not fall within the scope of protection of the claimed invention, but which is useful for understanding the invention. In particular, this fourth embodiment does not fall within the scope of protection of the independent claims.

[0094] Because device 1''' is structurally and functionally similar to device 1, it will be described below only in those aspects that distinguish device 1''' from device 1, and where possible, corresponding parts and components will be designated with the same reference numerals.

[0095] Specifically, device 1''' differs from device 1 in that it defines a movable portion 6 and comprises an insert 13 configured to be positioned in an intervening position between the shaped portion 4 and the plurality of layers 3 to support at least a portion of the second flange 2c, and preferably the entire second flange 2c, in the initial configuration during the aforementioned lamination (Figure 7A).

[0096] During use, the insert 13 can be displaced in an automated manner, for example using the aforementioned robot, from an interposed position defining the aforementioned rest position to an external position relative to the plurality of layers 3, so that the second flange 2c is interposed between the insert 13 and the molded part 4 (Figure 7B).

[0097] The insert 13 is movable from an external position to a compression position that defines the aforementioned bending position to compress the second flange 2c against the forming portion and displace the second flange 2c from its initial configuration to its final configuration (shown in FIG. 7C).

[0098] Preferably, the insert 13 is movable in an automated manner, for example by means of a robot 20, which in this case defines the aforementioned actuator means.

[0099] Alternatively, the insert 13 may be manually displaced by an operator from the interposed position to the external position.

[0100] This particular embodiment has the further advantage that, thanks to the presence of insert 13 interposed between molded part 4 and layer 3, layer 3 itself can also be laminated to the mold using robot 20, i.e., to molded part 4 shaped in a "Z-shape," as can be seen in Figures 7A, 7B, and 7C.

[0101] In the absence of the insert 13, it would in fact be complicated for the compression roller (known per se and not shown in detail) of the robot 20 to stack the layer 3 at the right angle interior corner, i.e. where the second flange 2c extends from the web 2a.

[0102] Therefore, thanks to the presence of the insert 13, it is possible to obtain a structural element 2 with a Z-shaped profile in an automated manner using a common Z-shaped mold (molding part 4), which can then be carried out in an automated stacking process using an automatic robot 20.

[0103] Conveniently, during use, the laminated layers 3 and the insert 13 displaced to its external position are contained in a vacuum chamber 14 defined between a vacuum bag 15 (of a known type and not described in detail) and the molding part 4 (and therefore between the vacuum bag 15 and the forming mold).

[0104] At this point, a vacuum is applied inside the vacuum chamber 14 to displace the insert 13 from an external position to a compressed position to cause bending of the second flange 2c in the initial configuration and optionally bending of a portion of the web 2a from the initial configuration to the final configuration.

[0105] From a closer inspection of the characteristics of the devices 1, 1', 1'' and the manufacturing methods realized by the invention, the advantages that the invention can obtain become clear.

[0106] In particular, the device 1, 1', 1'' and the manufacturing method according to the invention make it possible to realize a structural element 2 of composite material with a Z-shaped cross section (profile) using operations that can be easily automated, thereby increasing the degree of automation of the manufacturing process of said structural element 2, while at the same time allowing said process to be carried out through the manual intervention of an operator when and where deemed appropriate.

[0107] Indeed, the actuator means 7, 7', 7'' arranged to move the movable portion 6 may be driven either automatically or manually through the intervention of an operator.

[0108] This provides a very flexible manufacturing process.

[0109] Furthermore, the construction of the devices 1, 1', 1'' is made very simple with respect to known automated manufacturing devices, which are often bulky and expensive.

[0110] It is evident that the devices 1, 1', 1'' and methods described and illustrated herein may be subject to improvements and modifications without departing from the scope of protection defined by the claims.

[0111] Specifically, the movable portion 6 may be moved manually by an operator. [Explanation of symbols]

[0112] 1, 1', 1'', 1''' device 2 Structural Elements 2a Central Web 2b, 2c Wings, flanges 3, 3a, 3b, 3c layers 4 Molding section 5 Fixed part 6 Movable parts 7, 7' Actuator means 7'' Elastic return means 8, 8' piston 8'' spring 10 Guideway system 11 Contact body 12 hinge 13 Insert 14 Vacuum chamber 15 vacuum bags 20 Programmable Robots D Longitudinal direction R radius of curvature

Claims

1. 1. A method for manufacturing a structural element (2) of composite material extending along a straight or curved longitudinal direction (D) and having a Z-shaped cross section with respect to said longitudinal direction (D), which in its final configuration comprises a central web (2a) and two flanges (2b, 2c) extending from both end portions of said web (2a) in opposite directions at a given final angle, comprising: a) placing multiple layers (3) of composite material into a forming portion (4) of a mold; b) stacking the layers (3) on the forming part (4) such that at least a portion of the web (2a) is disposed in its final configuration, a first flange (2b) is disposed in its final configuration at the final angle relative to the portion of the web (2a) disposed in its final configuration, and a second flange (2c) is disposed in its initial configuration at an initial angle different from the final angle relative to the portion of the web (2a) disposed in its final configuration; c) moving a movable part (6) of the mould, which is movable from a rest position to a bending position relative to a fixed part (5) of the mould, said fixed part (5) and said movable part (6) together defining said mould section (4), said mould section (4) being defined in part by an outer mould surface of said fixed part (5) and in part by an outer mould surface of said movable part (6); d) displacing said second flange (2c) from said initial configuration to a final configuration at said final angle relative to said portion of said web (2a) disposed in its final configuration; Including, The laminating step b) is carried out by placing the second flange (2c) on the movable part (6), the displacing step d) is performed using the moving step c), The step a) of placing is carried out by positioning the second flange (2c) on the movable part (6), said step c) of moving comprises releasing the elastic return means (8'') from a deformed state to a non-deformed state; method.

2. The step c) of moving comprises: e) pressing the second flange (2c) with the movable part (6), The displacing step d) comprises:

10. The method of claim 1, further comprising the step of: f) folding the second flange (2c) from the initial configuration to the final configuration with movement of the movable part (6) from the rest position to the folding position.

3. 3. The method according to claim 1 or 2, wherein the moving step c) comprises activating a hydrodynamic or electrodynamic actuator (8, 8').

4. h) placing the abutment (11) against the layers (3) so that at least the web (2a) is interposed between the abutment (11) and the shaped portion (4); i) moving the abutment (11) towards the forming section (4) to compress at least the web (2a); further comprising 4. The method according to claim 1, wherein the displacing step d) is performed by pushing the second flange (2c) with the movable part (6) until the second flange (2c) abuts the abutment body (11).

5. A device (1, 1', 1'') for manufacturing a structural element (2) of composite material, extending along a straight or curved longitudinal direction (D), having a Z-shaped cross section with respect to said longitudinal direction (D), comprising a plurality of layers (3) of composite material, and having, in its final configuration, a central web (2a) and two flanges (2b, 2c) extending from both end portions of said web (2a) in opposite directions at a given final angle, the device (1, 1', 1'') comprises a mold having a molding portion (4) configured to support the plurality of layers (3) of composite material, the plurality of layers (3) of composite material being configured to be arranged in the molding portion (4) and laminated together in use such that at least a portion of the web (2a) is arranged in its final configuration, the first flange (2b) is arranged in its final configuration at the final angle relative to the portion of the web (2a) arranged in its final configuration, and the second flange (2c) is arranged in its initial configuration at an initial angle different from the final angle relative to the portion of the web (2a) arranged in its final configuration, the initial angle being larger than the final angle; said device (1, 1', 1''), in particular said mold, comprises a fixed part (5) and a movable part (6) movable relative to said fixed part (5), said fixed part (5) and said movable part (6) together defining said shaping part (4), said shaping part (4) being defined in part by an outer shaping surface of said fixed part (5) and in part by an outer shaping surface of said movable part (6); the second flange (2c) is configured to be positioned and stacked on the movable portion (6); the movable portion (6) is configured to be moved from a rest position to a bending position to move the second flange (2c) from the initial configuration to the final configuration; a resilient return means (8'') interposed between the fixed part (5) and the movable part (6) and configured to be released from a deformed position to a non-deformed position in order to drive the movement of the movable part (6) from the rest position to the bent position, device(1,1',1'').

6. 6. The device (1, 1') according to claim 5, comprising a hydrodynamic or electrodynamic actuator (8, 8') drivable to move the movable part (6) from the rest position to the bent position.

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