WO2024256778A1 - Method for manufacturing a component for fitting out an aircraft cabin - Google Patents

Method for manufacturing a component for fitting out an aircraft cabin Download PDF

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Publication number
WO2024256778A1
WO2024256778A1 PCT/FR2024/050762 FR2024050762W WO2024256778A1 WO 2024256778 A1 WO2024256778 A1 WO 2024256778A1 FR 2024050762 W FR2024050762 W FR 2024050762W WO 2024256778 A1 WO2024256778 A1 WO 2024256778A1
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WO
WIPO (PCT)
Prior art keywords
manufacturing
component
mold
pressure
temperature
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Ceased
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PCT/FR2024/050762
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French (fr)
Inventor
Jeremy Cailleteau
Shuai CARTON
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Safran Seats SA
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Safran Seats SA
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Publication of WO2024256778A1 publication Critical patent/WO2024256778A1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
    • B29B17/0042—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/18—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length in the form of a mat, e.g. sheet moulding compound [SMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/545—Perforating, cutting or machining during or after moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0081—Shaping techniques involving a cutting or machining operation before shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/465—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating by melting a solid material, e.g. sheets, powders of fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/502—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] by first forming a mat composed of short fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0854—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/26—Scrap or recycled material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • B29L2031/3079—Cockpits, canopies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/771—Seats

Definitions

  • TITLE METHOD FOR MANUFACTURING A COMPONENT FOR THE FITTING OF AN AIRCRAFT CABIN
  • the invention relates to the technical field of components for fitting out an aircraft cabin, such components being intended, for example, to equip seats.
  • the technical background includes in particular documents DE-A1-102012003001, US-A1-2012/208419, US-A1-2011/036481, US-A1-4,946,526 and JP-A-S63 125315.
  • Such a material generally comprises fibres embedded in a polymer matrix.
  • a polymer matrix For example, it is known to use glass fibres, carbon fibres, etc.
  • Other materials are known for the production of such components, such as aluminium or plastic.
  • carbon fibers are widely used in the production of woven composite material parts in the aeronautics field, in particular woven composite blades of turbojets.
  • the layers of warp and weft threads are released as a preform of the composite material part is created, in order to achieve the different desired thicknesses.
  • a cutting operation is carried out. The cut carbon threads then become scraps from the weaving process.
  • carbon fibre offcuts have mechanical performance that is still intact because they have not been stressed. They can therefore be reused for the manufacture of new composite reinforcements.
  • carbon fibre offcuts were hardly ever used. Although sectors for reprocessing such carbon fibre offcuts have developed, they are saturated with demand, particularly from the automotive industry.
  • Carbon fibre offcuts are therefore not highly valued and outlets for the reuse of such fibres are still not very developed. They are mostly pyrolysed and then ground into powder constituting fillers for primers, paints or thermoplastic materials.
  • the research and development work supported focuses in particular on lightening the devices, particularly through the materials used and lightened on-board equipment.
  • the product comes in the form of a roll of a strip or a non-woven layer containing scraps of carbon fibers and a binder ensuring the cohesion of the fibers between them and the holding of the strip.
  • the invention therefore aims to provide a method for manufacturing a component for fitting out an aircraft cabin, by recycling carbon fibre scraps.
  • the invention is the result of technological research aimed at significantly improving the performance of aircraft and, in this sense, contributes to reducing the environmental impact of aircraft.
  • the invention thus proposes to recover fiber scraps, such as carbon fibers, and thus to recycle them.
  • the invention therefore makes it possible to produce development components from recycled material, which is particularly advantageous from an environmental and economic point of view.
  • noble aeronautical materials such as carbon fibers makes it possible to have an isotropic or quasi-isotropic non-woven structure, particularly in the plane, with properties similar to those produced from a woven structure, for example in glass fibers, while significantly reducing the mass of the product.
  • the term “furnishing component” should be understood as being a secondary structure component, in particular used to equip a seat, a piece of furniture, a storage chest or a trim panel for example. Such a component may have one or more functions chosen from: an aesthetic finish, a fixing, etc.
  • the term “non-woven layer” should be understood as being a layer composed of fibers, in particular carbon fibers, in particular with thermoplastic fibers, which are not woven together and which have a random orientation in the non-woven layer. The fibers of the non-woven layer are bound together by at least one binder, a binding material and/or a matrix, in particular a thermoplastic matrix, which ensures a certain cohesion of the non-woven layer.
  • Thermocompression is a combination of heat treatment and compression treatment, which can, for example, be carried out in a press.
  • the heat treatment is carried out, in particular, at a temperature greater than or equal to the glass transition and/or melting temperature of the binder and/or thermoplastic fibers.
  • the present invention may include other features, described in the following, which may be considered independently or in combination with each other:
  • the stack of non-woven layers is heated by convection (e.g. IR) or ceramic;
  • the mold is configured to form at least one variable thickness, a rib, a groove and/or a hole;
  • the binder is poly(phenylene sulfide) (PPS), polyetherimides (PEI), polyetheretherketone (PEEK), polycarbonate (PC), polyethersulfone (PESU) and/or polyphenylsulfone (PPSU);
  • PPS poly(phenylene sulfide)
  • PEI polyetherimides
  • PEEK polyetheretherketone
  • PC polycarbonate
  • PESU polyethersulfone
  • PPSU polyphenylsulfone
  • - compression step b) includes and/or is followed by a step of overmolding the component
  • - said fiber falls have a random orientation; - the component is intended to equip a seat in an aircraft cabin or is a component of such a seat;
  • the mold is heated from a first temperature to a plateau at a second temperature, then is cooled to a third temperature, and/or b2) the pressure in the mold increases from a first pressure to a plateau at a second pressure, then decreases to a third pressure
  • o is heated before increasing the pressure in the mold, and/or o is cooled before decreasing the pressure in the mold;
  • the second temperature is greater than or equal to the glass transition and/or melting temperature of the binder, in particular greater than or equal to 350°C, and/or
  • the second pressure is greater than or equal to 30 bars.
  • the first pressure is obtained either by evacuating the impression, in particular by mechanically closing the impressions and/or by pressurizing under pressure, in particular between 0.7 bar and 5 bar.
  • the present invention also relates to a component, in particular for fitting out an aircraft cabin, in particular for a seat of an aircraft cabin, manufactured by a manufacturing method as described above.
  • the manufacturing method according to the invention which is particularly advantageous for the purpose of reducing the environmental impact of aircraft, relates to a fitting component for an aircraft cabin, such as a seat element, in particular a shell, a seat, a backrest, an armrest and/or a tablet obtained by a manufacturing method as described above.
  • a seat element such as a shell, a seat, a backrest, an armrest and/or a tablet obtained by a manufacturing method as described above.
  • the component is preferably a seat component of an aircraft cabin.
  • Figure 1 is a schematic view of a pile of carbon fiber scraps
  • Figure 2 is a schematic view of a non-woven layer of carbon fiber scraps
  • FIG.3 is a very schematic cross-sectional view of a thermocompression mold used in the context of a manufacturing method according to the invention
  • Figure 4 is a graph illustrating the evolution of the pressure and temperature in the mold, according to a first embodiment of the invention
  • Figure 5 is a graph illustrating the evolution of the pressure and temperature in the mold, according to a second embodiment of the invention.
  • Figure 6 includes schematic perspective views of a component for fitting out an aircraft cabin, manufactured by a manufacturing method according to the invention.
  • Figure 1 is a schematic view of a cluster of carbon fiber scraps 10.
  • Carbon fiber scraps have a length less than or equal to 100mm and, in general, between 10mm and 50mm.
  • the invention proposes to recycle them by producing components for fitting out an aircraft cabin.
  • a component 12 of this type is illustrated in Figure 6.
  • the component 12 is, for example, intended to equip an aircraft seat.
  • Figure 2 is a schematic view of a non-woven layer of carbon fiber scraps.
  • the component 12 is made from fiber scraps, in particular carbon fibers, in the form of a layer or a non-woven strip 14, as illustrated in FIG. 2.
  • component 12 is made from a mixture of fiber scraps, thermoplastic fibers and a binder.
  • Thermoplastic fibers have a length less than or equal to 100mm, and generally between 10mm and 50mm.
  • the fiber scraps 10 are used to make a non-woven layer 14, as shown in Figure 2.
  • the step of carrying out the manufacturing method, during which the non-woven layer 14 is produced may comprise at least: i) a collection step, during which fiber scraps 10, in particular carbon fiber scraps, are recovered; ii) a disentangling step, during which the fibers 10, in particular the carbon fibers, are disentangled and may be mixed with a binder; iii) a dispersion step, during which a flow of dry air is used to disperse the fibers 10; iv) a manufacturing step, during which a fiber mat is produced, the fiber mat comprising the fibers 10, air and the binder; and v) a calendering step, during which the fiber mat is hot calendered to a temperature greater than or equal to the glass transition temperature of the binder, so as to produce a semi-finished recycling product in the form of a roll of non-woven strip or layer 14.
  • the fiber scraps 10, in particular carbon fibers result from the cutting of blanks of parts made of composite materials in the aeronautical field, such blanks being obtained in particular by three-dimensional weaving of carbon fibers using a loom as mentioned above.
  • the disentangling step ii) consists in disentangling the fibers 10 and, optionally, mixing them with a binder, in particular at low temperature.
  • the binder may be in the form of particles and/or fibers, for example of a resin-based thermoplastic type, such as polyethylene (PE), polypropylene (PP) or in a PE-PP copolymer.
  • the disentangling step ii) may further comprise a mixture of the fibers 10, in particular carbon fibers, with thermoplastic fibers, such as polyetherimides (PEI), poly(phenylene sulfide) (PPS) or polycarbonate (PC).
  • thermoplastic fibers such as polyetherimides (PEI), poly(phenylene sulfide) (PPS) or polycarbonate (PC).
  • PEI polyetherimides
  • PPS poly(phenylene sulfide)
  • PC polycarbonate
  • the thermoplastic fibers preferably have a glass transition temperature higher than that of the binder.
  • the calendering step iv) is carried out at the glass transition temperature of the binder and is intended not to soften the thermoplastic fibres intended to be softened during subsequent processing.
  • the semi-finished product can be used to manufacture a finished product after further processing, in particular heating to the glass transition temperature of the thermoplastic fibers, such as hot molding of the non-woven web.
  • the dispersion step iii) and the manufacturing step iv) of the manufacturing process make it possible, using a flow of dry air, to disperse the fibers 10 and to produce a fiber mat comprising the fibers 10, air and the binder.
  • the calendering step v) then makes it possible to produce the semi-finished recycling product in the form of a roll of non-woven strip 14.
  • the manufacturing method according to the invention essentially comprises at least: a) a cutting step, during which several non-woven layers 14 are cut and stacked, in order to form a stack of non-woven layers, b) a compression step, during which the stack of non-woven layers is thermocompressed in a mold, so as to produce a component having a non-planar shape.
  • non-woven layers 14 respectively comprise scraps of fibres 10, in particular carbon fibres, held, at least punctually, with a binder, in particular thermoplastic, ensuring cohesion of the non-woven layer 14.
  • the non-woven layers 14 may also comprise thermoplastic fibres.
  • the non-woven layers 14 may have the same composition.
  • the fiber scraps 10 generally have a length less than or equal to 100mm, and in particular between 5mm and 50mm, in particular between 12.5mm and 25mm.
  • the term “binder” must be understood as being an element making it possible to ensure cohesion of the non-woven layer 14, such as a binding material and/or a matrix.
  • the stack may consist of a non-woven mattress and/or non-woven flakes, which may be composed of cut pieces of non-woven mattress.
  • the non-woven layer 14 preferably has a thickness of between 0.1 mm and 0.6 mm, and preferably of between 0.2 mm and 0.4 mm.
  • the non-woven layer 14 may be associated with a binder, in particular a thermoplastic or a thermosetting material.
  • the thermoplastic binder may, for example, be poly(sulfide phenylene sulfone (PPS), polyetherimides (PEI), polyetheretherketone (PEEK), polycarbonate (PC), polyethersulfone (PESU) and/or polyphenylsulfone (PPSU).
  • Thermoplastic fibers preferably have a glass transition or melting temperature higher than that of the binder.
  • the non-woven layer 14 may have a surface density of between 100g/m 2 and 1000g/m 2 , in particular between 200g/m 2 and 600g/m 2 .
  • Figure 3 is a very schematic cross-sectional view of a thermocompression mold used in the context of a manufacturing method according to the invention. More particularly, Figure 3 illustrates very schematically for the implementation of the compression step b) of the manufacturing method according to the invention.
  • two presses 16 are arranged next to each other and each receiving a set of imprints 20a and 20b with a stack of non-woven layers 14 for the production of two components 12.
  • the press 16 comprises two parts, respectively an upper part 16a and a lower part 16b, between which the stack of non-woven layers 14 is arranged.
  • the upper part 16a and the lower part 16b comprise imprints 20a and 20b for forming the component 12.
  • the imprints 20a and 20b may be fixed, removable or movable in the upper part 16a and the lower part 16b of the press 16.
  • a stack of non-woven layers 14 is arranged in each set of imprints 20a and 20b of the presses 16, so as to best fill the volume of a material chamber defined inside the imprints 20a and 20b.
  • the stacking is mass controlled, in order to obtain the required mass, dimensions and thicknesses of the components 12.
  • the set of imprints 20a and 20b is equipped with a compression chamber allowing the stack of non-woven layers 14 to be encapsulated, in particular very swollen when cold.
  • the imprints 20a and 20b have a limited thickness, so as to be heated quickly, and sufficiently thick, so as to be sufficiently rigid for compliant dimensioning.
  • the imprints 20a and 20b have a thickness of between 5 mm and 20 mm.
  • Figure 6 includes schematic perspective views of a component for fitting out an aircraft cabin, manufactured by a manufacturing method according to the invention.
  • the component 12 has a non-planar shape, in particular a complex three-dimensional shape.
  • the stack of non-woven layers 12 is heated, in particular by conduction, by the mold 16.
  • the heating is preferably carried out at a temperature above the glass transition and/or melting temperature of the binder, impregnating the fibers, in particular carbon fibers.
  • the mold 16 is preferably configured to form at least one variable thickness, rib, groove, and/or hole in the component 12.
  • an insert may be intended to be fixed to the component 12.
  • the insert is previously positioned in the mold 16.
  • figures 4 and 5 are graphs illustrating the evolution of the pressure and the temperature in the mold, respectively, according to a first and a second embodiment of the invention.
  • the mold 16 is heated from a first temperature T1 to a level at a second temperature T2, then is cooled to a third temperature T3;
  • the pressure in the mold 16 increases from a first pressure P1 to a level at a second pressure P2, then decreases to a third pressure P3.
  • the mold 16 may be heated prior to increasing the pressure in the mold 16. Furthermore, the mold 16 may be cooled prior to decreasing the pressure in the mold 16.
  • the increase and/or decrease in temperature T, respectively during heating and cooling, can be linear.
  • the increase and decrease in pressure can each be instantaneous, near-instantaneous, or substantially instantaneous.
  • the first pressure P1 is between 0.5 bar and 5 bars
  • the second pressure P2 is greater than or equal to 30 bars, in particular between 30 bars and 70 bars, and/or
  • the third pressure P3 is between 0.5 bar and 5 bars.
  • the first temperature T1 is in particular between 20°C and 60°C,
  • the second temperature T2 is in particular greater than or equal to the glass transition or melting temperature of the binder, in particular greater than or equal to 350°C, in particular between 350°C and 400°C, and/or
  • the third temperature T3 is in particular between 20°C and 60°C.
  • the duration of the temperature stage is in particular between 5min and 15min, in particular approximately 10min,
  • the heating time i.e. the increase from the first temperature T1 to the second temperature T2 is in particular between 3 min and 30 min, and/or
  • the cooling time i.e. the reduction from the second temperature T2 to the third temperature T3, is in particular between 5 min and 20 min.
  • the mold 16 may comprise a consolidation press regulated at a fourth temperature T4, lower than the solidification temperature of the binder with upper part 16a and lower part 16b of the mold 16.
  • the heating of the manufacturing process according to the invention is carried out by a heating means, of the conduction type, of the convection type, in particular infrared, or of the ceramic type.
  • the imprints 20a and 20b in which the stack of non-woven layers 14 is arranged for the formation of the component 12, are mobile, in particular mounted on a carriage, so as to be able to pass between different stations, such as, in particular, a stack loading station, a heating station, a consolidation station and an unloading station.
  • the present invention provides several advantages including: - a reduction in material losses (particularly carbon fibers) during the composite manufacturing cycle in the aeronautics sector,

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Abstract

The invention relates to a method for manufacturing a component (12), in particular for fitting out an aircraft cabin, in particular for a seat of an aircraft cabin, comprising at least: a) a cutting step, in which a plurality of nonwoven layers (14), comprising fibre scraps with at least one binder, are cut and stacked, in order to form a stack of nonwoven layers, and b) a compression step, in which the stack of nonwoven layers is thermocompressed in a mould (16), so as to produce a component (12) having a non-planar shape.

Description

DESCRIPTION DESCRIPTION

TITRE : PROCÉDÉ DE FABRICATION D’UN COMPOSANT D’AMENAGEMENT D’UN HABITACLE D’AERONEF TITLE: METHOD FOR MANUFACTURING A COMPONENT FOR THE FITTING OF AN AIRCRAFT CABIN

Domaine technique de l’invention Technical field of the invention

L’invention a trait au domaine technique des composants d’aménagement d’un habitacle d’aéronefs, de tels composants étant par exemple destinés à équiper des sièges. The invention relates to the technical field of components for fitting out an aircraft cabin, such components being intended, for example, to equip seats.

Arrière-plan technique Technical background

L’arrière-plan technique comprend notamment les documents DE-A1 -102012003001 , US-A1 -2012/208419, US-A1 -2011/036481 , US-A1 -4,946,526 et JP-A-S63 125315.The technical background includes in particular documents DE-A1-102012003001, US-A1-2012/208419, US-A1-2011/036481, US-A1-4,946,526 and JP-A-S63 125315.

L’utilisation de matériaux composites pour la réalisation de composants d’aménagement d’un habitacle d’aéronef est bien connue. Un tel matériau comprend, en général, des fibres noyées dans une matrice polymérique. Il est, par exemple, connu d’utiliser des fibres de verre, de carbone, etc. D’autres matériaux sont connus pour la réalisation de tels composants, comme l’aluminium ou le plastique. The use of composite materials for the production of components for fitting out an aircraft cabin is well known. Such a material generally comprises fibres embedded in a polymer matrix. For example, it is known to use glass fibres, carbon fibres, etc. Other materials are known for the production of such components, such as aluminium or plastic.

La consommation des fibres de carbone a significativement augmenté au cours des dix dernières années. La production s’est adaptée de manière à répondre à la demande croissante. Consumption of carbon fibers has increased significantly over the last ten years. Production has adapted to meet the growing demand.

Majoritairement employées dans les structures composites, les fibres de carbone sont très utilisées dans la production des pièces en matériaux composites tissés dans le domaine aéronautique, notamment les aubes composites tissées des turboréacteurs. Au cours de leur fabrication, les couches de fils de chaînes et trames sont libérées au fur et à mesure de la création d’une préforme de la pièce en matériaux composites, afin d’atteindre les différentes épaisseurs désirées. Lorsque la préforme est libérée du métier, une opération de découpe est réalisée. Les fils de carbone coupés deviennent alors des chutes du procédé de tissage. Mainly used in composite structures, carbon fibers are widely used in the production of woven composite material parts in the aeronautics field, in particular woven composite blades of turbojets. During their manufacture, the layers of warp and weft threads are released as a preform of the composite material part is created, in order to achieve the different desired thicknesses. When the preform is released from the loom, a cutting operation is carried out. The cut carbon threads then become scraps from the weaving process.

Ainsi, les chutes de fibres de carbone représentent un potentiel volume important sur l’ensemble des usines de production. Thus, carbon fiber waste represents a potentially significant volume across all production plants.

Par ailleurs, les chutes de fibres de carbone possèdent des performances mécaniques encore intactes car elles n’ont pas été sollicitées. Elles peuvent donc être réutilisées pour la fabrication de nouveaux renforts composites. Or, jusqu’à il y a peu, les chutes de fibres de carbone n’étaient pratiquement pas valorisées. En effet, bien que des filières de retraitement de telles chutes de fibres de carbone se soient développées, elles sont saturées de demandes, notamment en provenance de l’automobile. Furthermore, the carbon fibre offcuts have mechanical performance that is still intact because they have not been stressed. They can therefore be reused for the manufacture of new composite reinforcements. However, until recently, carbon fibre offcuts were hardly ever used. Although sectors for reprocessing such carbon fibre offcuts have developed, they are saturated with demand, particularly from the automotive industry.

Les chutes de fibres de carbone sont donc peu valorisées et des débouchés pour la réutilisation de telles fibres sont encore peu développés. Elles sont pour la plupart pyrolysées puis broyées en poudre constituant des charges pour les apprêts, les peintures ou les matériaux thermoplastiques. Carbon fibre offcuts are therefore not highly valued and outlets for the reuse of such fibres are still not very developed. They are mostly pyrolysed and then ground into powder constituting fillers for primers, paints or thermoplastic materials.

Le changement climatique est une préoccupation majeure pour de nombreux organes législatifs et de régulation à travers le monde. En effet, diverses restrictions sur les émissions de carbone ont été, sont ou seront adoptées par divers états. Climate change is a major concern for many legislative and regulatory bodies around the world. Indeed, various restrictions on carbon emissions have been, are being or will be adopted by various states.

En particulier, une norme ambitieuse s’applique à la fois aux nouveaux types d’aéronefs mais aussi ceux en circulation nécessitant de devoir mettre en œuvre des solutions technologiques afin de les rendre conformes aux réglementations en vigueur. L’aviation civile se mobilise depuis maintenant plusieurs années pour apporter une contribution à la lutte contre le changement climatique. In particular, an ambitious standard applies both to new types of aircraft and to those in circulation requiring the implementation of technological solutions in order to make them compliant with current regulations. Civil aviation has been mobilizing for several years now to make a contribution to the fight against climate change.

Les efforts de recherche technologique ont déjà permis d’améliorer de manière très significative les performances environnementales des aéronefs. Technological research efforts have already made it possible to significantly improve the environmental performance of aircraft.

Les travaux de recherche et de développement soutenus portent notamment sur l’allègement des appareils, notamment par les matériaux employés et les équipements embarqués allégés. The research and development work supported focuses in particular on lightening the devices, particularly through the materials used and lightened on-board equipment.

Il a donc été envisagé de valoriser des chutes de fibres de carbone afin de mettre en place une nouvelle filière. À cet égard, les efforts de recherche et de développement ont permis de mettre au point un produit semi-fini de recyclage à base de chutes de fibres de carbone et d’un procédé de fabrication d’un tel produit. It was therefore considered to valorize carbon fiber scraps in order to set up a new sector. In this regard, research and development efforts have made it possible to develop a semi-finished recycling product based on carbon fiber scraps and a manufacturing process for such a product.

Le produit se présente sous la forme d’un rouleau d’une bande ou une couche intissée comportant des chutes de fibres de carbone et un liant assurant la cohésion des fibres entre elles et la tenue de la bande. The product comes in the form of a roll of a strip or a non-woven layer containing scraps of carbon fibers and a binder ensuring the cohesion of the fibers between them and the holding of the strip.

Cependant, à ce jour, aucune mesure visant à exploiter un tel produit n’a été entreprise. L’invention vise donc à fournir un procédé de fabrication d’un composant d’aménagement d’un habitacle d’aéronef, par recyclage de chutes de fibres de carbone. A cet effet, l'invention est le résultat des recherches technologiques visant à améliorer de manière très significative les performances des avions et, en ce sens, contribue à la réduction de l’impact environnemental des avions. However, to date, no measures aimed at exploiting such a product have been undertaken. The invention therefore aims to provide a method for manufacturing a component for fitting out an aircraft cabin, by recycling carbon fibre scraps. To this end, the invention is the result of technological research aimed at significantly improving the performance of aircraft and, in this sense, contributes to reducing the environmental impact of aircraft.

Résumé de l’invention Summary of the invention

Pour cela, l’invention un procédé de fabrication d’un composant notamment pour un aménagement d’un habitacle d’aéronef, comprenant au moins : a) une étape de découpe, au cours de laquelle plusieurs couches intissées, comportant des chutes de fibres ayant avantageusement une orientation aléatoire avec au moins un liant, sont découpées et empilées, afin de former un empilement de couches intissées, et b) une étape de compression, au cours de laquelle l’empilement de couches intissées est thermocomprimé dans un moule, de façon à réaliser un composant ayant une forme non plane. For this, the invention provides a method for manufacturing a component, in particular for fitting out an aircraft cabin, comprising at least: a) a cutting step, during which several non-woven layers, comprising fiber scraps advantageously having a random orientation with at least one binder, are cut and stacked, in order to form a stack of non-woven layers, and b) a compression step, during which the stack of non-woven layers is thermocompressed in a mold, so as to produce a component having a non-planar shape.

Selon l’invention, les couches intissées peuvent comporter chacune des chutes de fibres, notamment de fibres de carbone, et de fibres thermoplastiques, notamment tenues ponctuellement, avec un liant, en particulier en thermoplastique, qui assure une cohésion de la couche intissée. According to the invention, the non-woven layers may each comprise scraps of fibers, in particular carbon fibers, and thermoplastic fibers, in particular held punctually, with a binder, in particular thermoplastic, which ensures cohesion of the non-woven layer.

Par ailleurs, selon l’invention, les couches intissées peuvent avoir notamment une même composition. Furthermore, according to the invention, the non-woven layers may have the same composition.

L’invention propose ainsi de valoriser les chutes de fibres, telles que les fibres de carbone et ainsi de les recycler. L’invention permet donc de réaliser des composants d’aménagement à partir de matériau recyclé, ce qui est particulièrement avantageux d’un point de vue environnemental et économique. The invention thus proposes to recover fiber scraps, such as carbon fibers, and thus to recycle them. The invention therefore makes it possible to produce development components from recycled material, which is particularly advantageous from an environmental and economic point of view.

Le recyclage de matière noble aéronautique comme les fibres de carbone permet d’avoir une structure non-tissée isotrope ou quasi-isotrope, notamment dans le plan, avec des propriétés similaires à celles produites à partir de structure tissée, par exemple en fibres de verre, tout en réduisant de manière significative la masse du produit. The recycling of noble aeronautical materials such as carbon fibers makes it possible to have an isotropic or quasi-isotropic non-woven structure, particularly in the plane, with properties similar to those produced from a woven structure, for example in glass fibers, while significantly reducing the mass of the product.

Dans la présente description, le terme « composant d’aménagement » doit être entendu comme étant un composant de structure secondaire, notamment servant à équiper un siège, un meuble, un coffre de rangement ou un panneau d’habillage par exemple. Un tel composant peut avoir une ou plusieurs fonctions choisies parmi : une finition esthétique, une fixation, etc. De plus, dans la présente description, le terme « couche intissée » doit être entendu comme étant un couche composée de fibres, en particulier de fibres de carbone, notamment avec des fibres thermoplastiques, qui ne sont pas tissées entre elles et qui ont une orientation aléatoire dans la couche intissée. Les fibres de la couche intissée sont liées entre elles par au moins un liant, une matière liante et/ou une matrice, en particulier une matrice thermoplastique, qui assure une certaine cohésion de la couche intissée. In this description, the term "furnishing component" should be understood as being a secondary structure component, in particular used to equip a seat, a piece of furniture, a storage chest or a trim panel for example. Such a component may have one or more functions chosen from: an aesthetic finish, a fixing, etc. Furthermore, in the present description, the term "non-woven layer" should be understood as being a layer composed of fibers, in particular carbon fibers, in particular with thermoplastic fibers, which are not woven together and which have a random orientation in the non-woven layer. The fibers of the non-woven layer are bound together by at least one binder, a binding material and/or a matrix, in particular a thermoplastic matrix, which ensures a certain cohesion of the non-woven layer.

L’orientation aléatoire des fibres est particulièrement avantageuse car elle permet à la couche d’avoir les mêmes propriétés dans toutes les directions (isotrope ou quasi- isotrope). The random orientation of the fibers is particularly advantageous because it allows the layer to have the same properties in all directions (isotropic or quasi-isotropic).

Une thermocompression est une combinaison d’un traitement thermique et d’un traitement de compression, qui peut, par exemple, être réalisée sous presse. Thermocompression is a combination of heat treatment and compression treatment, which can, for example, be carried out in a press.

Le traitement thermique est réalisé, en particulier, à une température supérieure ou égale à la température de transition vitreuse et/ou de fusion du liant et/ou des fibres thermoplastiques. The heat treatment is carried out, in particular, at a temperature greater than or equal to the glass transition and/or melting temperature of the binder and/or thermoplastic fibers.

La présente invention peut comprendre d’autres caractéristiques, décrites dans ce qui suit, qui peuvent être considérées indépendamment ou en combinaison les unes avec les autres : The present invention may include other features, described in the following, which may be considered independently or in combination with each other:

- l’empilement de couches intissées est placé dans un jeu d’empreintes du moule à l’étape b) ; - the stack of non-woven layers is placed in a set of mold impressions in step b);

- l’empilement de couches intissées est chauffé par conduction par le moule ; - the stack of non-woven layers is heated by conduction through the mold;

- l’empilement de couches intissées est chauffé par convection (par exemple IR) ou céramique ; - the stack of non-woven layers is heated by convection (e.g. IR) or ceramic;

- le moule est configuré pour former au moins une épaisseur variable, une nervure, une rainure et/ou un trou ; - the mold is configured to form at least one variable thickness, a rib, a groove and/or a hole;

- un insert destiné à être fixé au composant est préalablement positionné dans le moule avant l’étape de compression b) ; - an insert intended to be fixed to the component is previously positioned in the mold before the compression step b);

- le liant est du poly(sulfure de phénylène) (PPS), du polyétherimides (PEI), du polyétheréthercétone (PEEK), du polycarbonate (PC), du polyéthersulfone (PESU) et/ou du polyphénylsulfone (PPSU) ; - the binder is poly(phenylene sulfide) (PPS), polyetherimides (PEI), polyetheretherketone (PEEK), polycarbonate (PC), polyethersulfone (PESU) and/or polyphenylsulfone (PPSU);

- l’étape de compression b) comprend et/ou est suivie par une étape de surmoulage du composant ; - compression step b) includes and/or is followed by a step of overmolding the component;

- lesdites chutes de fibres ont une orientation aléatoire ; - le composant est destiné à équiper un siège d’un habitacle d’aéronef ou est un composant d’un tel siège ; - said fiber falls have a random orientation; - the component is intended to equip a seat in an aircraft cabin or is a component of such a seat;

- lors de l’étape de compression b) b1 ) le moule est chauffé depuis une première température jusqu’à un palier à une deuxième température, puis est refroidi jusqu’à une troisième température, et/ou b2) la pression dans le moule augmente d’une première pression à un palier à une deuxième pression, puis diminue jusqu’à une troisième pression, - in the compression step b) b1) the mold is heated from a first temperature to a plateau at a second temperature, then is cooled to a third temperature, and/or b2) the pressure in the mold increases from a first pressure to a plateau at a second pressure, then decreases to a third pressure,

- le moule : o est chauffé avant l’augmentation de la pression dans le moule, et/ou o est refroidi avant la diminution de la pression dans le moule ; - the mold: o is heated before increasing the pressure in the mold, and/or o is cooled before decreasing the pressure in the mold;

- l’augmentation, respectivement la réduction, de la température est linéaire ; - the increase, respectively the reduction, of the temperature is linear;

- l’augmentation, respectivement la réduction, de la pression est sensiblement instantanée ; - the increase, respectively the reduction, of the pressure is substantially instantaneous;

- la deuxième température est supérieure ou égale à la température de transition vitreuse et/ou de fusion du liant, notamment supérieure ou égale à 350°C, et/ou- the second temperature is greater than or equal to the glass transition and/or melting temperature of the binder, in particular greater than or equal to 350°C, and/or

- la deuxième pression est supérieure ou égale à 30 bars. - the second pressure is greater than or equal to 30 bars.

En particulier, la première pression, respectivement la troisième pression, est obtenue soit par mise au vide de l’empreinte, notamment par fermeture mécanique des empreintes et/ou par mise en pression sous presse, en particulier comprise entre 0.7 bar et 5 bars. In particular, the first pressure, respectively the third pressure, is obtained either by evacuating the impression, in particular by mechanically closing the impressions and/or by pressurizing under pressure, in particular between 0.7 bar and 5 bar.

La présente invention concerne encore un composant, notamment pour un aménagement d’un habitacle d’aéronef, en particulier pour un siège d’un habitacle d’aéronef, fabriqué par un procédé de fabrication tel que décrit ci-dessus. The present invention also relates to a component, in particular for fitting out an aircraft cabin, in particular for a seat of an aircraft cabin, manufactured by a manufacturing method as described above.

Par ailleurs, le procédé de fabrication selon l'invention, particulièrement avantageux dans le but de réduire l’impact environnemental des aéronefs, concerne un composant d’aménagement pour un habitacle d’aéronef, tel qu’un élément de siège, en particulier une coque, une assise, un dossier, un accoudoir et/ou une tablette obtenu par un procédé de fabrication tel que décrit dans ce qui précède. Furthermore, the manufacturing method according to the invention, which is particularly advantageous for the purpose of reducing the environmental impact of aircraft, relates to a fitting component for an aircraft cabin, such as a seat element, in particular a shell, a seat, a backrest, an armrest and/or a tablet obtained by a manufacturing method as described above.

Le composant est de préférence un composant de siège d’un habitacle d’aéronef. The component is preferably a seat component of an aircraft cabin.

Brève description des figures Brief description of the figures

La présente invention sera mieux comprise et d’autres objets, caractéristiques et avantages de l’invention apparaîtront plus clairement à la lecture de la description qui suit, comprenant des exemples de réalisation de composant pour l’aménagement présentés en tant qu’exemples non limitatifs qui pourront servir à compléter la compréhension de la présente invention et l’exposé de sa réalisation et, le cas échéant, contribuer à sa définition. Cette description détaillée faite en référence aux figures annexées, dans lesquelles : The present invention will be better understood and other objects, characteristics and advantages of the invention will appear more clearly on reading the description which follows, including examples of embodiments of components for the arrangement presented as non-limiting examples which may serve to complete the understanding of the present invention and the description of its embodiment and, where appropriate, contribute to its definition. This detailed description is made with reference to the appended figures, in which:

[Fig.1 ] la figure 1 est une vue schématique d’un amas de chutes de fibres de carbone ; [Fig.2] la figure 2 est une vue schématique d’une couche intissée de chutes de fibres de carbone ; [Fig.1] Figure 1 is a schematic view of a pile of carbon fiber scraps; [Fig.2] Figure 2 is a schematic view of a non-woven layer of carbon fiber scraps;

[Fig.3] la figure 3 est une vue très schématique en coupe d’un moule de thermocompression utilisé dans le cadre d’un procédé de fabrication selon l’invention ; [Fig.4] la figure 4 est un graphe illustrant l’évolution de la pression et de la température dans le moule, selon un premier mode de réalisation de l’invention ; [Fig.3] Figure 3 is a very schematic cross-sectional view of a thermocompression mold used in the context of a manufacturing method according to the invention; [Fig.4] Figure 4 is a graph illustrating the evolution of the pressure and temperature in the mold, according to a first embodiment of the invention;

[Fig.5] la figure 5 est un graphe illustrant l’évolution de la pression et de la température dans le moule, selon un deuxième mode de réalisation de l’invention ; et [Fig.5] Figure 5 is a graph illustrating the evolution of the pressure and temperature in the mold, according to a second embodiment of the invention; and

[Fig.6] la figure 6 comprend des vues schématiques en perspective d’un composant d’aménagement d’un habitacle d’aéronef, fabriqué par un procédé de fabrication selon l’invention. [Fig.6] Figure 6 includes schematic perspective views of a component for fitting out an aircraft cabin, manufactured by a manufacturing method according to the invention.

Description détaillée de l’invention Detailed description of the invention

La figure 1 est une vue schématique d’un amas de chutes de fibres de carbone 10.Figure 1 is a schematic view of a cluster of carbon fiber scraps 10.

Les chutes de fibres de carbone ont une longueur inférieure ou égale à 100mm et, en général, comprise entre 10mm et 50mm. Carbon fiber scraps have a length less than or equal to 100mm and, in general, between 10mm and 50mm.

Plutôt que de mettre au rebus les chutes de fibres de carbone, l’invention propose de les valoriser en réalisant des composants pour l’aménagement d’un habitacle d’aéronef. Un composant 12 de ce type étant illustré à la figure 6. Le composant 12 est, par exemple, destiné à équiper un siège d’aéronef. Rather than discarding carbon fiber scraps, the invention proposes to recycle them by producing components for fitting out an aircraft cabin. A component 12 of this type is illustrated in Figure 6. The component 12 is, for example, intended to equip an aircraft seat.

La figure 2 est une vue schématique d’une couche intissée de chutes de fibres de carbone. Figure 2 is a schematic view of a non-woven layer of carbon fiber scraps.

Selon l’invention, le composant 12 est réalisé à partir de chutes de fibres, notamment de fibres de carbone, se présentant sous la forme d’une couche ou d’une bande intissée 14, comme illustré à la figure 2. According to the invention, the component 12 is made from fiber scraps, in particular carbon fibers, in the form of a layer or a non-woven strip 14, as illustrated in FIG. 2.

Plus spécifiquement, le composant 12 est réalisé à partir d’un mélange de chutes de fibres, de fibres thermoplastiques et d’un liant. More specifically, component 12 is made from a mixture of fiber scraps, thermoplastic fibers and a binder.

Les fibres thermoplastiques ont une longueur inférieure ou égale à 100mm, et en général comprise entre 10mm et 50mm. Les chutes de fibres 10 sont utilisées pour réaliser une couche intissée 14, telle que représentée à la figure 2. Thermoplastic fibers have a length less than or equal to 100mm, and generally between 10mm and 50mm. The fiber scraps 10 are used to make a non-woven layer 14, as shown in Figure 2.

L’étape de réalisation du procédé de fabrication, au cours de laquelle la couche intissée 14 est réalisée, peut comprendre au moins : i) une étape de collecte, au cours de laquelle des chutes de fibres 10, notamment des chutes de fibres de carbone, sont récupérées ; ii) une étape de démêlage, au cours de laquelle les fibres 10, notamment les fibres de carbone, sont démêlées et peuvent être mélangées avec un liant ; iii) une étape de dispersion, au cours de laquelle un flux d’air sec est utilisé pour disperser les fibres 10 ; iv) une étape de confection, au cours de laquelle un matelas de fibres est réalisé, le matelas de fibres comportant les fibres 10, de l’air et le liant ; et v) une étape de calandrage, au cours de laquelle le matelas de fibres est calandré à chaud jusqu’à une température supérieure ou égale à la température de transition vitreuse du liant, de façon à réaliser un produit semi-fini de recyclage sous la forme d’un rouleau de bande ou couche intissée 14. The step of carrying out the manufacturing method, during which the non-woven layer 14 is produced, may comprise at least: i) a collection step, during which fiber scraps 10, in particular carbon fiber scraps, are recovered; ii) a disentangling step, during which the fibers 10, in particular the carbon fibers, are disentangled and may be mixed with a binder; iii) a dispersion step, during which a flow of dry air is used to disperse the fibers 10; iv) a manufacturing step, during which a fiber mat is produced, the fiber mat comprising the fibers 10, air and the binder; and v) a calendering step, during which the fiber mat is hot calendered to a temperature greater than or equal to the glass transition temperature of the binder, so as to produce a semi-finished recycling product in the form of a roll of non-woven strip or layer 14.

Avantageusement, à l’étape de collecte i), les chutes de fibres 10, notamment de fibres de carbone, résultent de la découpe d’ébauches de pièces en matériaux composites dans le domaine aéronautique, de telles ébauches étant notamment obtenues par tissage en trois dimensions de fibres de carbone au moyen d’un métier à tisser comme évoqué dans ce qui précède. Advantageously, in the collection step i), the fiber scraps 10, in particular carbon fibers, result from the cutting of blanks of parts made of composite materials in the aeronautical field, such blanks being obtained in particular by three-dimensional weaving of carbon fibers using a loom as mentioned above.

L’étape de démêlage ii) consiste à démêler les fibres 10 et, optionnellement à les mélanger avec un liant, en particulier à basse température. Le liant peut se présenter sous la forme de particules et/ou de fibres, par exemple de type thermoplastique à base de résine, tel que le polyéthylène (PE), le polypropylène (PP) ou dans un copolymère PE-PP. The disentangling step ii) consists in disentangling the fibers 10 and, optionally, mixing them with a binder, in particular at low temperature. The binder may be in the form of particles and/or fibers, for example of a resin-based thermoplastic type, such as polyethylene (PE), polypropylene (PP) or in a PE-PP copolymer.

L’étape de démêlage ii) peut en outre comprendre un mélange des fibres 10, notamment des fibres de carbone, avec des fibres thermoplastiques, tel que les polyétherimides (PEI), le poly(sulfure de phénylène) (PPS) ou le polycarbonate (PC). Les fibres thermoplastiques ont, de préférence, une température de transition vitreuse supérieure à celle du liant. The disentangling step ii) may further comprise a mixture of the fibers 10, in particular carbon fibers, with thermoplastic fibers, such as polyetherimides (PEI), poly(phenylene sulfide) (PPS) or polycarbonate (PC). The thermoplastic fibers preferably have a glass transition temperature higher than that of the binder.

L’étape de calandrage iv) est réalisé à la température de transition vitreuse du liant et est destinée à ne pas ramollir les fibres thermoplastiques destinées à être ramollies lors d’une transformation postérieure. En présence des fibres thermoplastiques, le produit semi-fini peut être utilisé pour fabriquer un produit fini après une nouvelle transformation, en particulier un chauffage à la température de transition vitreuse des fibres thermoplastiques, tel qu’un moulage à chaud de la bande intissée. The calendering step iv) is carried out at the glass transition temperature of the binder and is intended not to soften the thermoplastic fibres intended to be softened during subsequent processing. In the presence of the thermoplastic fibers, the semi-finished product can be used to manufacture a finished product after further processing, in particular heating to the glass transition temperature of the thermoplastic fibers, such as hot molding of the non-woven web.

L’étape de dispersion iii) et l’étape de confection iv) du procédé de fabrication permettent, grâce à un flux d’air sec, de disperser les fibres 10 et de réaliser un matelas de fibres comportant les fibres 10, de l’air et le liant. The dispersion step iii) and the manufacturing step iv) of the manufacturing process make it possible, using a flow of dry air, to disperse the fibers 10 and to produce a fiber mat comprising the fibers 10, air and the binder.

L’étape de calandrage v) permet alors de réaliser le produit semi-fini de recyclage sous la forme d’un rouleau de bande intissée 14. The calendering step v) then makes it possible to produce the semi-finished recycling product in the form of a roll of non-woven strip 14.

Le procédé de fabrication selon l’invention comprend pour l’essentiel au moins : a) une étape de découpe, au cours de laquelle plusieurs couches intissées 14 sont découpées et empilées, afin de former un empilement de couches intissées, b) une étape de compression, au cours de laquelle l’empilement de couches intissées est thermocomprimé dans un moule, de façon à réaliser un composant ayant une forme non plane. The manufacturing method according to the invention essentially comprises at least: a) a cutting step, during which several non-woven layers 14 are cut and stacked, in order to form a stack of non-woven layers, b) a compression step, during which the stack of non-woven layers is thermocompressed in a mold, so as to produce a component having a non-planar shape.

Par ailleurs, les couches intissées 14 comportent respectivement des chutes de fibres 10, notamment de fibres de de carbone, tenues, au moins ponctuellement, avec un liant, en particulier thermoplastique, assurant une cohésion de la couche intissées 14. De plus, les couches intissées 14peuvent également comporter de fibres thermoplastiques. Furthermore, the non-woven layers 14 respectively comprise scraps of fibres 10, in particular carbon fibres, held, at least punctually, with a binder, in particular thermoplastic, ensuring cohesion of the non-woven layer 14. In addition, the non-woven layers 14 may also comprise thermoplastic fibres.

Notamment, les couches intissées 14 peuvent présenter une même composition.In particular, the non-woven layers 14 may have the same composition.

Les chutes de fibres 10 ont en général une longueur inférieure ou égale à 100mm, et notamment comprise entre 5mm et 50mm, en particulier comprise entre 12.5mm et 25mm. The fiber scraps 10 generally have a length less than or equal to 100mm, and in particular between 5mm and 50mm, in particular between 12.5mm and 25mm.

Dans la présente description, le terme « liant » doit être entendu comme étant un élément permettant d’assurer une cohésion de la couche intissée 14, tel qu’une matière liante et/ou une matrice. In the present description, the term “binder” must be understood as being an element making it possible to ensure cohesion of the non-woven layer 14, such as a binding material and/or a matrix.

L’empilement peut être constitué d’un matelas de non tissé et/ou de flocon de non tissé, pouvant être composés de morceaux de matelas de non tissé découpés. The stack may consist of a non-woven mattress and/or non-woven flakes, which may be composed of cut pieces of non-woven mattress.

La couche intissée 14 a de préférence une épaisseur comprise entre 0,1 mm et 0,6mm, et de préférence comprise entre 0,2mm et 0,4mm. The non-woven layer 14 preferably has a thickness of between 0.1 mm and 0.6 mm, and preferably of between 0.2 mm and 0.4 mm.

La couche intissée 14 peut être associée à un liant, notamment un thermoplastique ou un thermodurcissable. Le liant thermoplastique peut, par exemple, être le poly(sulfure de phénylène) (PPS), le polyétherimides (PEI), le polyétheréthercétone (PEEK), le polycarbonate (PC), le polyéthersulfone (PESU) et/ou le polyphénylsulfone (PPSU).The non-woven layer 14 may be associated with a binder, in particular a thermoplastic or a thermosetting material. The thermoplastic binder may, for example, be poly(sulfide phenylene sulfone (PPS), polyetherimides (PEI), polyetheretherketone (PEEK), polycarbonate (PC), polyethersulfone (PESU) and/or polyphenylsulfone (PPSU).

Les fibres thermoplastiques ont, de préférence, une température de transition vitreuse ou de fusion supérieure à celle du liant. Thermoplastic fibers preferably have a glass transition or melting temperature higher than that of the binder.

La couche intissée 14 peut avoir une densité surfacique comprise entre 100g/m2 et 1000g/m2, en particulier entre 200g/m2 et 600g/m2. The non-woven layer 14 may have a surface density of between 100g/m 2 and 1000g/m 2 , in particular between 200g/m 2 and 600g/m 2 .

La figure 3 est une vue très schématique en coupe d’un moule de thermocompression utilisé dans le cadre d’un procédé de fabrication selon l’invention. Plus particulièrement, la figure 3 illustre de manière très schématique pour la mise en œuvre de l’étape de compression b) du procédé de fabrication selon l’invention. Figure 3 is a very schematic cross-sectional view of a thermocompression mold used in the context of a manufacturing method according to the invention. More particularly, Figure 3 illustrates very schematically for the implementation of the compression step b) of the manufacturing method according to the invention.

A cet effet, selon présenté à la figure 3, deux presses 16 sont disposées l’une à côté de l’autre et recevant chacune un jeu d’empreintes 20a et 20b avec un empilement de couches intissées 14 pour la réalisation de deux composants 12. For this purpose, as shown in Figure 3, two presses 16 are arranged next to each other and each receiving a set of imprints 20a and 20b with a stack of non-woven layers 14 for the production of two components 12.

De manière classique, la presse 16 comprend deux parties, respectivement une partie supérieure 16a et une partie inférieure 16b, entre lesquelles est disposé l’empilement de couches intissées 14. La partie supérieure 16a et la partie inférieure 16b comprennent des empreintes 20a et 20b pour la formation du composant 12. Conventionally, the press 16 comprises two parts, respectively an upper part 16a and a lower part 16b, between which the stack of non-woven layers 14 is arranged. The upper part 16a and the lower part 16b comprise imprints 20a and 20b for forming the component 12.

Les empreintes 20a et 20b peuvent être fixes, amovibles ou mobiles dans partie supérieure 16a et la partie inférieure 16b de la presse 16. The imprints 20a and 20b may be fixed, removable or movable in the upper part 16a and the lower part 16b of the press 16.

Un empilement de couches intissées 14 est disposé dans chaque jeu d’empreintes 20a et 20b des presses 16, de façon à remplir au mieux le volume d’une chambre matière définie à l’intérieur des empreintes 20a et 20b. A stack of non-woven layers 14 is arranged in each set of imprints 20a and 20b of the presses 16, so as to best fill the volume of a material chamber defined inside the imprints 20a and 20b.

En particulier, l’empilement est contrôlé en masse, afin d’obtenir une masse, des dimensions et des épaisseurs du composants 12 requises. In particular, the stacking is mass controlled, in order to obtain the required mass, dimensions and thicknesses of the components 12.

Le jeu d’empreintes 20a et 20b est équipé d’une chambre de compression permettant d’encapsuler l’empilement des couches intissées 14, en particulier très foisonnant à froid. The set of imprints 20a and 20b is equipped with a compression chamber allowing the stack of non-woven layers 14 to be encapsulated, in particular very swollen when cold.

Dans un mode particulier, les empreintes 20a et 20b présentent une épaisseur limitée, de façon à être chauffées rapidement, et suffisamment épaisse, de façon à être suffisamment rigides pour un dimensionnement conforme. Notamment, les empreintes 20a et 20b présentent une épaisseur comprise entre 5mm à 20mm. In a particular embodiment, the imprints 20a and 20b have a limited thickness, so as to be heated quickly, and sufficiently thick, so as to be sufficiently rigid for compliant dimensioning. In particular, the imprints 20a and 20b have a thickness of between 5 mm and 20 mm.

De plus, les jeu d’empreintes 20a et 20b peuvent être équipés d’un système de fermeture, notamment par le vide et/ou mécanique. La figure 6 comprend des vues schématiques en perspective d’un composant d’aménagement d’un habitacle d’aéronef, fabriqué par un procédé de fabrication selon l’invention. Comme cela est visible à la figure 6, le composant 12 a une forme non plane, notamment une forme complexe en trois dimensions. In addition, the sets of impressions 20a and 20b can be equipped with a closing system, in particular by vacuum and/or mechanical. Figure 6 includes schematic perspective views of a component for fitting out an aircraft cabin, manufactured by a manufacturing method according to the invention. As can be seen in Figure 6, the component 12 has a non-planar shape, in particular a complex three-dimensional shape.

A cet effet, l’empilement de couches intissées 12 est chauffé, notamment par conduction, par le moule 16. For this purpose, the stack of non-woven layers 12 is heated, in particular by conduction, by the mold 16.

Le chauffage est de préférence réalisé à une température supérieure à la température de transition vitreuse et/ou de fusion du liant, imprégnant les fibres, notamment les fibres de carbone. The heating is preferably carried out at a temperature above the glass transition and/or melting temperature of the binder, impregnating the fibers, in particular carbon fibers.

Le moule 16 est, de préférence, configuré pour former au moins une épaisseur variable, une nervure, une rainure et/ou un trou dans le composant 12. The mold 16 is preferably configured to form at least one variable thickness, rib, groove, and/or hole in the component 12.

Dans un cas particulier, un insert peut être destiné à être fixé au composant 12. A cet effet, l’insert est préalablement positionné dans le moule 16. In a particular case, an insert may be intended to be fixed to the component 12. For this purpose, the insert is previously positioned in the mold 16.

Selon l’invention, deux méthodes de gestion de la température et de la pression dans le moule 16. Plus particulièrement, les figures 4 et 5 sont des graphes illustrant l’évolution de la pression et de la température dans le moule, respectivement, selon un premier et un deuxième mode de réalisation de l’invention. According to the invention, two methods of managing the temperature and pressure in the mold 16. More particularly, figures 4 and 5 are graphs illustrating the evolution of the pressure and the temperature in the mold, respectively, according to a first and a second embodiment of the invention.

Les graphes des figures 4 et 5 montrent, The graphs in Figures 4 and 5 show,

- d’une part, l’évolution de la température T(°C) dans le moule 16 au cours du temps T(min) selon une courbe C1 , et - on the one hand, the evolution of the temperature T(°C) in the mold 16 over the time T(min) according to a curve C1, and

- d’autre part, l’évolution de la pression P(bar) dans le moule 16 au cours du temps T(min) selon une courbe C2. - on the other hand, the evolution of the pressure P(bar) in the mold 16 over time T(min) according to a curve C2.

Tel qu’illustré sur les graphes des figures 4 et 5 : As illustrated in the graphs in Figures 4 and 5:

- b1 ) le moule 16 est chauffé depuis une première température T1 jusqu’à un palier à une deuxième température T2, puis est refroidi jusqu’à une troisième température T3 ; et - b1) the mold 16 is heated from a first temperature T1 to a level at a second temperature T2, then is cooled to a third temperature T3; and

- b2) la pression dans le moule 16 augmente d’une première pression P1 à un palier à une deuxième pression P2, puis diminue jusqu’à une troisième pression P3. - b2) the pressure in the mold 16 increases from a first pressure P1 to a level at a second pressure P2, then decreases to a third pressure P3.

De plus, le moule 16 peut être chauffé avant l’augmentation de la pression dans le moule 16. Par ailleurs, le moule 16 peut être refroidi avant la diminution de la pression dans le moule 16. Additionally, the mold 16 may be heated prior to increasing the pressure in the mold 16. Furthermore, the mold 16 may be cooled prior to decreasing the pressure in the mold 16.

L’augmentation et/ou la réduction de la température T, respectivement lors du chauffage et du refroidissement, peuvent être linéaires. L’augmentation et la réduction de la pression peuvent être chacune instantanée, quasi- instantanée ou sensiblement instantanée. The increase and/or decrease in temperature T, respectively during heating and cooling, can be linear. The increase and decrease in pressure can each be instantaneous, near-instantaneous, or substantially instantaneous.

En particulier : Especially :

- la première pression P1 est comprise entre 0.5 bar et 5 bars, - the first pressure P1 is between 0.5 bar and 5 bars,

- la deuxième pression P2 est supérieure ou égale à 30 bars, notamment comprise entre 30 bars et 70 bars, et/ou - the second pressure P2 is greater than or equal to 30 bars, in particular between 30 bars and 70 bars, and/or

- la troisième pression P3 est comprise entre 0.5 bar et 5 bars. - the third pressure P3 is between 0.5 bar and 5 bars.

Par ailleurs, Moreover,

- la première température T1 est en particulier comprise entre 20°C et 60°C,- the first temperature T1 is in particular between 20°C and 60°C,

- la deuxième température T2 est en particulier supérieure ou égale à la température de transition vitreuse ou de fusion du liant, notamment supérieure ou égale à 350°C, en particulier comprise entre 350°C et 400°C, et/ou - the second temperature T2 is in particular greater than or equal to the glass transition or melting temperature of the binder, in particular greater than or equal to 350°C, in particular between 350°C and 400°C, and/or

- la troisième température T3 est en particulier comprise entre 20°C et 60°C. - the third temperature T3 is in particular between 20°C and 60°C.

De plus, Moreover,

- la durée du palier de température est en particulier comprise entre 5min et 15min, notamment sensiblement de 10min, - the duration of the temperature stage is in particular between 5min and 15min, in particular approximately 10min,

- la durée de chauffage, c’est-à-dire d’augmentation de la première température T1 à la deuxième température T2, est en particulier comprise entre 3min et 30min, et/ou- the heating time, i.e. the increase from the first temperature T1 to the second temperature T2, is in particular between 3 min and 30 min, and/or

- la durée de refroidissement, c’est-à-dire de diminution de la deuxième température T2 et à la troisième température T3, est en particulier comprise entre 5min et 20min.- the cooling time, i.e. the reduction from the second temperature T2 to the third temperature T3, is in particular between 5 min and 20 min.

Dans un mode alternatif de l’invention, le moule 16 peut comprendre une presse de consolidation régulée à une quatrième température T4, inférieure la température de solidification du liant avec partie supérieure 16a et la partie inférieure 16b du moule 16. In an alternative embodiment of the invention, the mold 16 may comprise a consolidation press regulated at a fourth temperature T4, lower than the solidification temperature of the binder with upper part 16a and lower part 16b of the mold 16.

Par ailleurs, le chauffage du procédé de fabrication selon l’invention est réalisé par un moyen de chauffe, du type conduction, de type convection, notamment infra rouge, ou du type céramique. Furthermore, the heating of the manufacturing process according to the invention is carried out by a heating means, of the conduction type, of the convection type, in particular infrared, or of the ceramic type.

De plus, les empreintes 20a et 20b, dans lesquelles est disposé l’empilement de couches intissées 14 pour la formation du composant 12 sont mobiles, notamment montés sur un chariot, de façon à être aptes à passer entre entres différents postes, tels que, notamment, un poste de chargement de l’empilement, un poste de chauffe, un poste de consolidation et un poste déchargement. In addition, the imprints 20a and 20b, in which the stack of non-woven layers 14 is arranged for the formation of the component 12, are mobile, in particular mounted on a carriage, so as to be able to pass between different stations, such as, in particular, a stack loading station, a heating station, a consolidation station and an unloading station.

La présente invention apporte plusieurs avantages parmi lesquels : - une réduction des pertes de matière (notamment de fibres de carbone) durant le cycle de fabrication composite dans le domaine aéronautique, The present invention provides several advantages including: - a reduction in material losses (particularly carbon fibers) during the composite manufacturing cycle in the aeronautics sector,

- un recyclage de cette matière pour les composants d’aménagement intérieurs d’un aéronef, comme les sièges d’avion, - une réduction de la masse de ces composants d’aménagement ainsi obtenus et, par conséquence, une réduction de l’empreinte carbone liée au transport aérien,- recycling of this material for the interior fittings of an aircraft, such as aircraft seats, - a reduction in the mass of these fittings thus obtained and, consequently, a reduction in the carbon footprint linked to air transport,

- etc. - etc.

Claims

REVENDICATIONS 1 . Procédé de fabrication d’un composant (12), notamment pour un aménagement d’un habitacle d’aéronef, en particulier pour un siège d’un habitacle d’aéronef, comprenant au moins : a) une étape de découpe, au cours de laquelle plusieurs couches intissées (14), comportant des chutes de fibres ayant une orientation aléatoire avec au moins un liant, sont découpées et empilées, afin de former un empilement de couches intissées, et b) une étape de compression, au cours de laquelle l’empilement de couches intissées est thermocomprimé dans un moule (16), de façon à réaliser un composant (12) ayant une forme non plane. 1. Method for manufacturing a component (12), in particular for fitting out an aircraft cabin, in particular for a seat of an aircraft cabin, comprising at least: a) a cutting step, during which several non-woven layers (14), comprising fiber scraps having a random orientation with at least one binder, are cut and stacked, in order to form a stack of non-woven layers, and b) a compression step, during which the stack of non-woven layers is thermocompressed in a mold (16), so as to produce a component (12) having a non-planar shape. 2. Procédé de fabrication selon la revendication 1 , dans lequel l’empilement de couches intissées est chauffé par conduction par le moule (16), par convection ou céramique. 2. Manufacturing method according to claim 1, in which the stack of non-woven layers is heated by conduction by the mold (16), by convection or ceramic. 3. Procédé de fabrication selon l’une quelconque des revendications précédentes, dans lequel le moule (16) est configuré pour former au moins une épaisseur variable, une nervure, une rainure et/ou un trou. 3. Manufacturing method according to any one of the preceding claims, in which the mold (16) is configured to form at least one variable thickness, a rib, a groove and/or a hole. 4. Procédé de fabrication selon l’une quelconque des revendications précédentes, dans lequel un insert destiné à être fixé au composant (14) est préalablement positionné dans le moule (16) avant l’étape de compression b). 4. Manufacturing method according to any one of the preceding claims, in which an insert intended to be fixed to the component (14) is previously positioned in the mold (16) before the compression step b). 5. Procédé de fabrication selon l’une quelconque des revendications précédentes, dans lequel le liant est du poly(sulfure de phénylène) (PPS), du polyétherimides (PEI), du polyétheréthercétone (PEEK), du polycarbonate (PC), du polyéthersulfone (PESU) et/ou du polyphénylsulfone (PPSU). 5. A manufacturing method according to any preceding claim, wherein the binder is poly(phenylene sulfide) (PPS), polyetherimides (PEI), polyetheretherketone (PEEK), polycarbonate (PC), polyethersulfone (PESU) and/or polyphenylsulfone (PPSU). 6. Procédé de fabrication selon l’une quelconque des revendications précédentes, dans lequel l’étape de compression b) comprend et/ou est suivie d’une étape de surmoulage du composant (12). 6. Manufacturing method according to any one of the preceding claims, in which the compression step b) comprises and/or is followed by a step of overmolding the component (12). 7. Procédé de fabrication selon l’une quelconque des revendications précédentes, dans lequel, lors de l’étape de compression b) : 7. Manufacturing method according to any one of the preceding claims, in which, during compression step b): - b1 ) le moule (16) est chauffé depuis une première température T 1 jusqu’à un palier à une deuxième température T2, puis est refroidi jusqu’à une troisième température T3, - b1) the mold (16) is heated from a first temperature T1 to a level at a second temperature T2, then is cooled to a third temperature T3, - b2) la pression dans le moule augmente d’une première pression P1 à un palier à une deuxième pression P2, puis diminue jusqu’à une troisième pression P3. - b2) the pressure in the mold increases from a first pressure P1 to a level at a second pressure P2, then decreases to a third pressure P3. 8. Procédé de fabrication selon la revendication 7, dans lequel le moule (16) :8. Manufacturing method according to claim 7, in which the mold (16): - est chauffé avant l’augmentation de la pression dans le moule (16), et/ou - is heated before increasing the pressure in the mold (16), and/or - est refroidi avant la diminution de la pression dans le moule (16). - is cooled before the pressure in the mold (16) is reduced. 9. Procédé de fabrication selon la revendication 7 ou 8, dans lequel l’augmentation, respectivement la réduction, de la température est linéaire. 9. Manufacturing method according to claim 7 or 8, in which the increase, respectively the reduction, of the temperature is linear. 10. Procédé de fabrication selon l’une quelconque des revendications 7 à 9, dans lequel l’augmentation, respectivement la réduction, de la pression est sensiblement instantanée. 10. Manufacturing method according to any one of claims 7 to 9, in which the increase, respectively the reduction, of the pressure is substantially instantaneous. 11. Procédé de fabrication selon l’une des revendications 7 à 10, dans lequel la deuxième température T2 est supérieure ou égale à la température de transition vitreuse et/ou de fusion du liant, notamment supérieure ou égale à 350°C, et/ou la deuxième pression P2 est supérieure ou égale à 30 bars. 11. Manufacturing method according to one of claims 7 to 10, in which the second temperature T2 is greater than or equal to the glass transition and/or melting temperature of the binder, in particular greater than or equal to 350°C, and/or the second pressure P2 is greater than or equal to 30 bars. 12. Procédé de fabrication selon l’une quelconques des revendications précédentes, dans lequel le composant est un composant de siège d’un habitacle d’aéronef. 12. Manufacturing method according to any one of the preceding claims, in which the component is a seat component of an aircraft cabin. 13. Procédé de fabrication selon l’une quelconques des revendications précédentes, dans lequel l’empilement de couches intissées est placé dans un jeu d’empreintes du moule à l’étape b). 13. Manufacturing method according to any one of the preceding claims, in which the stack of non-woven layers is placed in a set of imprints of the mold in step b). 14. Composant (12) notamment pour un aménagement d’un habitacle d’aéronef, caractérisé en ce que le composant (12) est obtenu par un procédé de fabrication selon l’une des revendications précédentes. 14. Component (12) in particular for fitting out an aircraft cabin, characterized in that the component (12) is obtained by a manufacturing method according to one of the preceding claims. 15. Composant (12) selon la revendication précédente, dans lequel le composant est un composant de siège d’un habitacle d’aéronef. 15. Component (12) according to the preceding claim, in which the component is a seat component of an aircraft cabin.
PCT/FR2024/050762 2023-06-16 2024-06-11 Method for manufacturing a component for fitting out an aircraft cabin Ceased WO2024256778A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FRFR2306202 2023-06-16
FR2306202A FR3149820B1 (en) 2023-06-16 2023-06-16 METHOD FOR MANUFACTURING A COMPONENT FOR THE FITTING OF AN AIRCRAFT CABIN

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JPS63125315A (en) 1986-11-14 1988-05-28 Toyota Auto Body Co Ltd Molding method for molding having complicated shape
US4946526A (en) 1987-10-29 1990-08-07 Ltv Aerospace And Defense Company Method for compression molding of laminated panels
US4948661A (en) * 1987-07-10 1990-08-14 C. H. Masland & Sons Glossy finish fiber reinforced molded product and processes of construction
US20110036481A1 (en) 2008-07-24 2011-02-17 Alenia Aeronautica S.P.A. method for recycling scraps of pregpreg materials
DE102010042349A1 (en) * 2010-10-12 2012-04-12 Benteler Sgl Gmbh & Co. Kg Manufacturing semi-finished textile product from carbon fibers obtained from matrix material, comprises manufacturing non-woven fabric and/or fleece, and impregnating non-woven fabric and/or fleece with matrix material
US20120208419A1 (en) 2011-02-14 2012-08-16 Dommes Henrik Process for producing semifinished fiber material
DE102012003001A1 (en) 2012-02-15 2013-08-22 Bayerische Motoren Werke Aktiengesellschaft Method for manufacturing fiber composite, particularly carbon fiber composite component for use in automotive industry, involves cutting fiber semi-finished part to form fiber layers with predetermined dimensions
US20160053788A1 (en) * 2014-08-22 2016-02-25 Toyota Jidosha Kabushiki Kaisha Component joining structure and component joining method
EP3643484A1 (en) * 2018-10-26 2020-04-29 Johns Manville System for producing a fully impregnated thermoplastic prepreg

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS63125315A (en) 1986-11-14 1988-05-28 Toyota Auto Body Co Ltd Molding method for molding having complicated shape
US4948661A (en) * 1987-07-10 1990-08-14 C. H. Masland & Sons Glossy finish fiber reinforced molded product and processes of construction
US4946526A (en) 1987-10-29 1990-08-07 Ltv Aerospace And Defense Company Method for compression molding of laminated panels
US20110036481A1 (en) 2008-07-24 2011-02-17 Alenia Aeronautica S.P.A. method for recycling scraps of pregpreg materials
DE102010042349A1 (en) * 2010-10-12 2012-04-12 Benteler Sgl Gmbh & Co. Kg Manufacturing semi-finished textile product from carbon fibers obtained from matrix material, comprises manufacturing non-woven fabric and/or fleece, and impregnating non-woven fabric and/or fleece with matrix material
US20120208419A1 (en) 2011-02-14 2012-08-16 Dommes Henrik Process for producing semifinished fiber material
DE102012003001A1 (en) 2012-02-15 2013-08-22 Bayerische Motoren Werke Aktiengesellschaft Method for manufacturing fiber composite, particularly carbon fiber composite component for use in automotive industry, involves cutting fiber semi-finished part to form fiber layers with predetermined dimensions
US20160053788A1 (en) * 2014-08-22 2016-02-25 Toyota Jidosha Kabushiki Kaisha Component joining structure and component joining method
EP3643484A1 (en) * 2018-10-26 2020-04-29 Johns Manville System for producing a fully impregnated thermoplastic prepreg

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FR3149820B1 (en) 2025-10-17

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