WO2024256779A1 - Method for manufacturing a component for the outfitting of an aircraft passenger cabin - Google Patents

Method for manufacturing a component for the outfitting of an aircraft passenger cabin Download PDF

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Publication number
WO2024256779A1
WO2024256779A1 PCT/FR2024/050763 FR2024050763W WO2024256779A1 WO 2024256779 A1 WO2024256779 A1 WO 2024256779A1 FR 2024050763 W FR2024050763 W FR 2024050763W WO 2024256779 A1 WO2024256779 A1 WO 2024256779A1
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WO
WIPO (PCT)
Prior art keywords
manufacturing
component
stack
fiber
during
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/FR2024/050763
Other languages
French (fr)
Inventor
Jeremy Cailleteau
Shuai CARTON
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Safran Seats SA
Original Assignee
Safran Seats SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Safran Seats SA filed Critical Safran Seats SA
Priority to EP24738018.1A priority Critical patent/EP4727758A1/en
Publication of WO2024256779A1 publication Critical patent/WO2024256779A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • 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
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • B29B17/0412—Disintegrating plastics, e.g. by milling to large particles, e.g. beads, granules, flakes, slices
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • 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
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/009—Shaping techniques involving a cutting or machining operation after 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72143—Fibres of discontinuous lengths
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • 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
    • B29K2105/06—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
    • B29K2105/128—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 in the form of a 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
    • B29K2105/26—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
    • B29L2031/771—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 -102010042349, EP-A1 -3 643 484, JP-A-S63 125315, US-A1 -2021/129453.
  • 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 also known for the production of such components, such as aluminium or plastic.
  • carbon fibers are widely used in the production of woven composite parts in the aeronautics sector, particularly woven composite blades for turbojets.
  • the layers of warp and weft threads are released as a preform of the composite part is created, in order to achieve the different desired thicknesses.
  • a cutting operation is carried out. The cut carbon threads then become offcuts from the weaving process.
  • carbon fiber waste represents a potentially significant volume across all production plants.
  • carbon fibre scraps have mechanical performance that is still intact, because they have not been stressed. They can therefore be reused for the manufacture of new composite material parts.
  • 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 Applicant takes into consideration the impact factors in all phases of design and development to obtain less energy-intensive, more environmentally friendly aeronautical components and products whose integration and use in civil aviation have moderate environmental consequences with the aim of improving the energy efficiency of aircraft.
  • 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 provides a method for manufacturing a component, in particular for fitting out an aircraft cabin, comprising at least: a) a production step, during which at least one non-woven layer comprising offcuts of fibers, in particular carbon fibers, impregnated with at least one binder, in particular thermoplastic, such as a thermoplastic matrix, which ensures cohesion of the non-woven layer, is produced; b) a consolidation step, during which the non-woven layer is consolidated, so as to obtain at least one fiber plate, in particular at least one laminated fiber plate; c) a cutting step, during which the plate is cut, and optionally, a superposition step, during which several cut fiber plates are superimposed and assembled together, so as to form a stack, in particular by welding them at several points by ultrasound; and d) a compression step, during which the fiber plate or stack is thermocompressed in a mold, so as to produce a component having a non-planar shape.
  • a production step during which at least one non-woven layer comprising offcut
  • 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
  • an isotropic or quasi-isotropic non-woven structure particularly in the plane, with similar properties to those produced from woven structures, for example glass fibres, whilst 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 and/or a trim panel for example. Such a component may have one or more functions chosen from an aesthetic finish, a fixing, etc.
  • non-woven layer should be understood as being a layer composed of 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.
  • 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).
  • Consolidation is to stiffen the non-woven layer and thus transform it into a relatively rigid plate. Consolidation can be a heat treatment, possibly associated with a compression treatment.
  • the heat treatment may be carried out at a temperature greater than or equal to the glass transition or melting temperature of the binder, the binder material and/or the matrix.
  • Thermocompression is a combination of heat treatment and compression treatment, which can, for example, be carried out in a press.
  • the present invention may include other features, described in the following, which may be considered independently or in combination with each other:
  • step c) the or each fiber plate is cut flat in step c) according to shapes corresponding to a development of the component
  • the fiber plates are assembled by ultrasonic welding in step c), in particular at several points, so as to form a stack of variable thickness and/or in developed form of the component; - the fiber plate and/or the stack is heated, in particular by infrared or ceramic convection;
  • the fiber plate and/or the stack is heated to a temperature greater than or equal to the glass transition or melting temperature of the binder, the binding material and/or the matrix, in particular the thermoplastic matrix;
  • the stack is heated, stamped and consolidated in the mold which is regulated at a temperature lower than the solidification temperature of the binder, the binding material and/or the matrix;
  • the mold is configured to form at least one variable thickness, a rib, a groove and/or a hole;
  • the mold is regulated at a temperature, in particular at a temperature lower than a solidification temperature of the binder
  • 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
  • the compression step d) includes and/or is followed by overmolding of the component
  • the cut and superimposed fiber plates are assembled by welding, in particular ultrasonic welding, in particular by point welding, to each other at the superposition stage, so that the stack is in one piece, in particular making it easier to handle the stack before thermocompression;
  • the component is intended to equip an aircraft seat or is a component of such a seat.
  • 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 particularly advantageous for the purpose of reducing the environmental impact of aircraft, relates to a component for fitting out 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.
  • the component is preferably a seat component of an aircraft cabin.
  • FIG. 1 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 Figure 3 are schematic views illustrating steps of a manufacturing method according to the invention.
  • Figure 4 is a schematic perspective view of a component for fitting out the passenger compartment of an aircraft, 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 10 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 4.
  • 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.
  • the manufacturing method according to the invention comprises at least: a) a production step, during which at least one non-woven layer 14 is produced, the non-woven layer 14 comprising fiber scraps 10, in particular carbon fiber scraps, in particular impregnated with a binder, or a binder material, for example thermoplastic, which ensures cohesion of the non-woven layer 14; b) a consolidation step, during which the non-woven layer 14 is consolidated, so as to obtain at least one fiber plate 18; c) a cutting step, during which the fiber plate 18 is cut and, optionally, a superposition step, during which several cut fiber plates 18 are superimposed and assembled together, so as to form a stack 20; and d) a compression step, during which the fiber plate 18 or the stack 20 is thermocompressed in a mold 16, so as to produce the component 12, in particular having a non-planar shape.
  • a production step during which at least one non-woven layer 14 is produced, the non-woven layer 14 comprising fiber scraps 10, in particular carbon fiber scraps,
  • 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 cut and superimposed fiber plates 18 are welded to each other in the superposition step, so that the stack 20 is in one piece. This makes it easier to handle the stack 20 with a view to carrying out the compression step d).
  • the cut and superimposed fiber plates 18 are assembled by ultrasonic welding, for example at several points, so as to form a stack of variable thickness and in development of the component 12.
  • 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 or a binder material; 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 fibre mat is produced, the fibre mat comprising the fibres 10, air and the binder or binding material; and v) a calendering step, during which the fibre 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 sub-step ii) consists in disentangling the fibers 10 and, optionally, mixing them with a binder, or a binding material, 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 sub-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).
  • Thermoplastic fibers preferably have a glass transition temperature higher than that of the binder.
  • the calendering sub-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 ill) 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 or binding material.
  • 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 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 or a binding material, in particular a thermoplastic or a thermoset.
  • the thermoplastic binder may, for example, be poly(phenylene sulfide) (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 includes schematic views illustrating several steps of the manufacturing method according to the invention.
  • Figure 3 illustrates very schematically the various stages of the manufacturing process from production stage a) to compression stage d).
  • Images 3a and 3b show step a) of the manufacturing process.
  • Image 3b further shows the consolidation step b), during which the fiber plate 18 is consolidated and obtained from the fiber scraps 10.
  • the consolidation preferably takes place by heating the non-woven layer 14 above the glass transition or melting temperature of the binder.
  • the mass fiber rate of the fiber plate 18 is between 40% and 60%, in particular between 45% and 55%, in particular substantially 50%.
  • Image 3c illustrates the cutting step c), in particular a cutting of the fiber plate 18 and, optionally, a superposition of several fiber plates 18 or several pieces of fiber plates cut to form the stack 20 by assembling them together.
  • the 3D image illustrates an intermediate step of heating the fiber plate 18 or the stack 20, in order to soften the fiber plate 18 or the stack 20. Such heating can be carried out at a temperature greater than or equal to the glass or melting temperature of the binder.
  • the fiber plate 18 or the stack 20 can be heated by conduction by the mold 16. Alternatively, the fiber plate 18 or the stack 20 can be heated by infrared or ceramic convection.
  • Image 3e illustrates the compression step d) consisting of an introduction of the fiber plate 18 or the stack 20 into the mold 16, in order to undergo thermocompression there.
  • the mold 16 comprises two parts, respectively an upper part 16a and a lower part 16b, between which the fiber plate 18 or the stack 20 is arranged.
  • the upper part 16a and the lower part 16b comprise imprints for forming the component 12.
  • the heated and flexible fiber plate 18 or stack 20 is stamped when the mold 16 is closed. As a result, the fiber plate 18 or the stack 20 is reconsolidated into a shaped part.
  • the mold 16 can be temperature regulated, in particular at a temperature lower than a solidification temperature of the polymer matrices.
  • Figure 4 is a schematic perspective view of the component 12 for an aircraft cabin layout, manufactured by the manufacturing method according to the invention.
  • component 12 has a non-planar shape, including a complex three-dimensional shape.
  • the mold 16 is preferably configured to form at least one variable thickness, rib, groove and/or hole in the component:
  • an insert may be intended to be fixed to the component 12.
  • the insert is previously positioned in the mold 16, before the consolidation step b).
  • Image 3f illustrates a stamping or embossing step.
  • the manufacturing method according to the invention may include an overmolding step, during which the component 12 is, at least in part, overmolded.
  • the overmolding step may be carried out with an injection polymer of the same nature as the polymer used as a binder or binding material for the fiber plate 18 or the stack 20.
  • the overmolding step can be carried out during compression step d) or after compression step d).

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Abstract

The invention relates to a method for manufacturing a component (12), in particular for outfitting an aircraft passenger cabin, comprising: a) a production step, during which at least one nonwoven layer (14) comprising waste fibres (10) impregnated with a binder is produced; b) a consolidation step, during which the nonwoven layer (14) is consolidated, so as to obtain at least one fibre sheet (18); c) a cutting step, during which the sheet (18) is cut out; and optionally, a superposition step, during which several cut-out fibre sheets (18) are superimposed and assembled with one another, so as to form a stack, d) a compression step, during which the fibre sheet (18) or the stack (20) 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 -102010042349, EP-A1 -3 643 484, JP-A-S63 125315, US-A1 -2021/129453. The technical background includes in particular documents DE-A1 -102010042349, EP-A1 -3 643 484, JP-A-S63 125315, US-A1 -2021/129453.

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 également 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 also 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 pièces 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 parts in the aeronautics sector, particularly woven composite blades for turbojets. During their manufacture, the layers of warp and weft threads are released as a preform of the composite 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 offcuts from the weaving process.

Ainsi, les chutes de fibres de carbone représentent un potentiel volume important sur l’ensemble des usines de production. 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 nouvelles pièces en matériaux composites. Thus, carbon fiber waste represents a potentially significant volume across all production plants. Furthermore, the carbon fibre scraps have mechanical performance that is still intact, because they have not been stressed. They can therefore be reused for the manufacture of new composite material parts.

Or, jusque récemment, 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. However, until recently, carbon fibre offcuts were hardly ever used. Indeed, 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.

La Déposante prend en considération les facteurs impactant dans toutes les phases de conception et de développement pour obtenir des composants et des produits aéronautiques moins énergivores, plus respectueux de l’environnement et dont l’intégration et l’utilisation dans l’aviation civile ont des conséquences environnementales modérées dans un but d’amélioration de l'efficacité énergétique des aéronefs. The Applicant takes into consideration the impact factors in all phases of design and development to obtain less energy-intensive, more environmentally friendly aeronautical components and products whose integration and use in civil aviation have moderate environmental consequences with the aim of improving the energy efficiency 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. 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. 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. 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. 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.

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. 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 réalisation, au cours de laquelle au moins une couche intissée comportant des chutes de fibres, notamment de fibres de carbone, imprégnées avec au moins un liant, en particulier en thermoplastique, tel qu’une matrice thermoplastique, qui assure une cohésion de la couche intissée, est réalisée ; b) une étape de consolidation, au cours de laquelle la couche intissée est consolidée, de façon à obtenir au moins une plaque de fibres, notamment au moins une plaque de fibres laminée ; c) une étape de découpe, au cours de laquelle la plaque est découpée, et optionnellement, une étape de superposition, au cours de laquelle plusieurs plaques de fibres découpées sont superposées et assemblées ensemble, de façon à former un empilement, en particulier en les soudant en plusieurs points par ultrason ; et d) une étape de compression, au cours de laquelle la plaque de fibres ou l’empilement est thermocomprimé(e) 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 production step, during which at least one non-woven layer comprising offcuts of fibers, in particular carbon fibers, impregnated with at least one binder, in particular thermoplastic, such as a thermoplastic matrix, which ensures cohesion of the non-woven layer, is produced; b) a consolidation step, during which the non-woven layer is consolidated, so as to obtain at least one fiber plate, in particular at least one laminated fiber plate; c) a cutting step, during which the plate is cut, and optionally, a superposition step, during which several cut fiber plates are superimposed and assembled together, so as to form a stack, in particular by welding them at several points by ultrasound; and d) a compression step, during which the fiber plate or stack is thermocompressed in a mold, so as to produce a component having a non-planar shape.

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 similar properties to those produced from woven structures, for example glass fibres, whilst 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 et/ou un panneau d’habillage par exemple. Un tel composant peut avoir une ou plusieurs fonctions choisies parmi une finition esthétique, une fixation, etc. 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 and/or a trim panel for example. Such a component may have one or more functions chosen from an aesthetic finish, a fixing, etc.

De plus, dans la présente description, le terme « couche intissée » doit être entendu comme étant une couche composée de fibres 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. Furthermore, in the present description, the term "non-woven layer" should be understood as being a layer composed of 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 consolidation a pour but de rigidifier la couche intissée et de la transformer ainsi en plaque relativement rigide. La consolidation peut être un traitement thermique, éventuellement associée à un traitement de compression. The purpose of consolidation is to stiffen the non-woven layer and thus transform it into a relatively rigid plate. Consolidation can be a heat treatment, possibly associated with a compression treatment.

Dans un tel cas, le traitement thermique peut être réalisé à une température supérieure ou égale à la température de transition vitreuse ou de fusion du liant, de la matière liante et/ou de la matrice. In such a case, the heat treatment may be carried out at a temperature greater than or equal to the glass transition or melting temperature of the binder, the binder material and/or the matrix.

Une thermocompression est une combinaison du traitement thermique et du 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.

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:

- la ou chaque plaque de fibres est découpée à plat à l’étape c) selon des formes correspondant à un développé du composant ; - the or each fiber plate is cut flat in step c) according to shapes corresponding to a development of the component;

- les plaques de fibres sont assemblées par soudure ultrason à l’étape c), notamment en plusieurs points, de façon à former un empilement d’épaisseur variable et/ou en développée du composant ; - la plaque de fibres et/ou l’empilement est chauffé(e), notamment par convection infra-rouge ou céramique ; - the fiber plates are assembled by ultrasonic welding in step c), in particular at several points, so as to form a stack of variable thickness and/or in developed form of the component; - the fiber plate and/or the stack is heated, in particular by infrared or ceramic convection;

- la plaque de fibres et/ou l’empilement est chauffé(e) à une température de supérieure ou égale à la température de transition vitreuse ou de fusion du liant, de la matière liante et/ou de la matrice, notamment de la matrice thermoplastique ; - the fiber plate and/or the stack is heated to a temperature greater than or equal to the glass transition or melting temperature of the binder, the binding material and/or the matrix, in particular the thermoplastic matrix;

- l’empilement est chauffé, embouti et consolidé dans le moule qui est régulé à une température inférieure à la température de solidification du liant, de la matière liante et/ou de la matrice ; - the stack is heated, stamped and consolidated in the mold which is regulated at a temperature lower than the solidification temperature of the binder, the binding material and/or the matrix;

- 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;

- le moule est régulé à une température, en particulier à une température inférieure à une température de solidification du liant ; - the mold is regulated at a temperature, in particular at a temperature lower than a solidification temperature of the binder;

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

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

- les plaques fibres découpées et superposées sont assemblées par soudage, notamment ultrason, en particulier par point, les unes aux autres à l’étape de superposition, de façon à ce que l’empilement soit monobloc, permettant en particulier de faciliter une manutention de l’empilement avant thermocompression ; - the cut and superimposed fiber plates are assembled by welding, in particular ultrasonic welding, in particular by point welding, to each other at the superposition stage, so that the stack is in one piece, in particular making it easier to handle the stack before thermocompression;

- lesdites chutes de fibres ont une orientation aléatoire ; et/ou - said fiber falls have a random orientation; and/or

- le composant est destiné à équiper un siège d’aéronef ou est un composant d’un tel siège. - the component is intended to equip an aircraft seat or is a component of such a seat.

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 d’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. Le composant est de préférence un composant de siège d’un habitacle d’aéronef. Furthermore, the manufacturing method according to the invention, particularly advantageous for the purpose of reducing the environmental impact of aircraft, relates to a component for fitting out 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. 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 following description, comprising examples of embodiments of components for the development 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 sont des vues schématiques illustrant des étapes d’un procédé de fabrication selon l’invention ; et [Fig.3] Figure 3 are schematic views illustrating steps of a manufacturing method according to the invention; and

[Fig.4] la figure 4 est une vue schématique en perspective d’un composant pour l’aménagement de l’habitacle d’un aéronef, fabriqué par un procédé de fabrication selon l’invention. [Fig.4] Figure 4 is a schematic perspective view of a component for fitting out the passenger compartment of an aircraft, 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 10 et 50mm. Carbon fiber scraps have a length less than or equal to 100mm and, in general, between 10 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 4. Le composant 12 est ; par exemple ; destins 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 4. 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.

Le procédé de fabrication selon l’invention comprend au moins : a) une étape de réalisation, au cours de laquelle au moins une couche intissée 14 est réalisée, la couche intissée 14 comportant des chutes de fibres 10, notamment des chutes de fibres de carbone, en particulier imprégnées avec un liant, ou une matière liante, par exemple en thermoplastique, qui assure une cohésion de la couche intissée 14 ; b) une étape de consolidation, au cours de laquelle la couche intissée 14 est consolidée, de façon à obtenir au moins une plaque de fibres 18 ; c) une étape de découpe, au cours de laquelle la plaque de fibres 18 est découpée et, optionnellement, une étape de superposition, au cours de laquelle plusieurs plaques de fibres 18 découpées sont superposées et assemblées ensemble, de façon à former un empilement 20 ; et d) une étape de compression, au cours de laquelle la plaque de fibres 18 ou l’empilement 20 est thermocomprimé(e) dans un moule 16, de façon à réaliser le composant 12, ayant en particulier une forme non plane. The manufacturing method according to the invention comprises at least: a) a production step, during which at least one non-woven layer 14 is produced, the non-woven layer 14 comprising fiber scraps 10, in particular carbon fiber scraps, in particular impregnated with a binder, or a binder material, for example thermoplastic, which ensures cohesion of the non-woven layer 14; b) a consolidation step, during which the non-woven layer 14 is consolidated, so as to obtain at least one fiber plate 18; c) a cutting step, during which the fiber plate 18 is cut and, optionally, a superposition step, during which several cut fiber plates 18 are superimposed and assembled together, so as to form a stack 20; and d) a compression step, during which the fiber plate 18 or the stack 20 is thermocompressed in a mold 16, so as to produce the component 12, in particular having a non-planar shape.

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.

En particulier, les plaques de fibres 18 découpées et superposées sont soudées les unes aux autres à l’étape de superposition, de façon à ce que l’empilement 20 soit monobloc. Ceci permet de faciliter une manutention de l’empilement 20 en vue de la réalisation de l’étape de compression d). In particular, the cut and superimposed fiber plates 18 are welded to each other in the superposition step, so that the stack 20 is in one piece. This makes it easier to handle the stack 20 with a view to carrying out the compression step d).

Notamment, les plaques de fibres 18 découpées et superposées sont assemblées par soudure ultrason, par exemple en plusieurs points, de façon à former un empilement d’épaisseur variable et en développé du composant 12. In particular, the cut and superimposed fiber plates 18 are assembled by ultrasonic welding, for example at several points, so as to form a stack of variable thickness and in development of the component 12.

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 ou une matière liante ; 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 ou la matière liante ; 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 or a binder material; 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 fibre mat is produced, the fibre mat comprising the fibres 10, air and the binder or binding material; and v) a calendering step, during which the fibre 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.

La sous-étape de démêlage ii) consiste à démêler les fibres 10 et, optionnellement à les mélanger avec un liant, ou une matière liante, 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 sub-step ii) consists in disentangling the fibers 10 and, optionally, mixing them with a binder, or a binding material, 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.

La sous-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).The disentangling sub-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).

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

La sous-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. The calendering sub-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.

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. In the presence of 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 ill) 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 ou la matière liante. The dispersion step ill) 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 or binding material.

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. 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 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 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 ou une matière liante, 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 or a binding material, in particular a thermoplastic or a thermoset. The thermoplastic binder may, for example, be poly(phenylene sulfide) (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 comprend des vues schématiques illustrant plusieurs étapes du procédé de fabrication selon l’invention. Figure 3 includes schematic views illustrating several steps of the manufacturing method according to the invention.

Plus particulièrement, la figure 3 illustre de manière très schématique les diverses étapes du procédé de fabrication de l’étape de réalisation a) à l’étape de compression d). More particularly, Figure 3 illustrates very schematically the various stages of the manufacturing process from production stage a) to compression stage d).

Les images 3a et 3b montre l’étape de réalisation a) du procédé de fabrication. Images 3a and 3b show step a) of the manufacturing process.

L’image 3b montre en outre l’étape de consolidation b), au cours de laquelle la plaque de fibres 18 est consolidée et obtenue à partir des chutes de fibres 10. La consolidation a, de préférence, lieu par chauffage de la couche intissée 14 au-delà de la température de transition vitreuse ou de fusion du liant. Image 3b further shows the consolidation step b), during which the fiber plate 18 is consolidated and obtained from the fiber scraps 10. The consolidation preferably takes place by heating the non-woven layer 14 above the glass transition or melting temperature of the binder.

Le taux de fibre massique de la plaque de fibres 18 est comprise entre 40% et 60%, notamment comprise entre 45% et 55%, en particulier de sensiblement 50%. The mass fiber rate of the fiber plate 18 is between 40% and 60%, in particular between 45% and 55%, in particular substantially 50%.

L’image 3c illustre l’étape de découpe c), en particulier une découpe de la plaque de fibres 18 et, éventuellement, une superposition de plusieurs plaques de fibres 18 ou plusieurs morceaux plaques de fibres découpés pour former l’empilement 20 en les assemblant ensemble. Image 3c illustrates the cutting step c), in particular a cutting of the fiber plate 18 and, optionally, a superposition of several fiber plates 18 or several pieces of fiber plates cut to form the stack 20 by assembling them together.

L’image 3d illustre une étape intermédiaire de chauffage de la plaque de fibres 18 ou de l’empilement 20, afin de ramollir la plaque de fibres 18 ou l’empilement 20. un tel chauffage peut être réalisé à une température supérieure ou égale à la température vitreuse ou de fusion du liant. La plaque de fibres 18 ou l’empilement 20 peut être chauffé(e) par conduction par le moule 16. En variante, la plaque de fibres 18 ou r’empilement 20 peut être chauffé(e) par convection infra-rouge ou céramique. L’image 3e illustre l’étape de compression d) consistant en une introduction de la plaque de fibres 18 ou de l’empilement 20 dans le moule 16, afin d’y subir une thermocompression. The 3D image illustrates an intermediate step of heating the fiber plate 18 or the stack 20, in order to soften the fiber plate 18 or the stack 20. Such heating can be carried out at a temperature greater than or equal to the glass or melting temperature of the binder. The fiber plate 18 or the stack 20 can be heated by conduction by the mold 16. Alternatively, the fiber plate 18 or the stack 20 can be heated by infrared or ceramic convection. Image 3e illustrates the compression step d) consisting of an introduction of the fiber plate 18 or the stack 20 into the mold 16, in order to undergo thermocompression there.

De manière classique, le moule 16 comprend deux parties, respectivement une partie supérieure 16a et une partie inférieure 16b, entre lesquelles est disposé la plaque de fibres 18 ou l’empilement 20. La parties supérieure 16a et la partie inférieure, 16b comprennent des empreintes pour la formation du composant 12. La plaque de fibres 18 ou l’empilement 20 chauffé(e) et souple est embouti lors de la fermeture du moule 16. Par suite, La plaque de fibres 18 ou l’empilement 20 est reconsolidé(e) en une pièce en forme. Conventionally, the mold 16 comprises two parts, respectively an upper part 16a and a lower part 16b, between which the fiber plate 18 or the stack 20 is arranged. The upper part 16a and the lower part 16b comprise imprints for forming the component 12. The heated and flexible fiber plate 18 or stack 20 is stamped when the mold 16 is closed. As a result, the fiber plate 18 or the stack 20 is reconsolidated into a shaped part.

Le moule 16 peut être régulé en température, en particulier à une température inférieure à une température de solidification des matrices polymérique. The mold 16 can be temperature regulated, in particular at a temperature lower than a solidification temperature of the polymer matrices.

La figure 4 est une vue schématique en perspective du composant 12 pour un aménagement de l’habitacle d’un aéronef, fabriqué par le procédé de fabrication selon l’invention. Figure 4 is a schematic perspective view of the component 12 for an aircraft cabin layout, manufactured by the manufacturing method according to the invention.

Plus particulièrement, comme cela est visible à la figure 4, le composant 12 a une forme non plane, notamment une forme complexe en trois dimensions. More particularly, as seen in Figure 4, component 12 has a non-planar shape, including a complex three-dimensional shape.

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 : The mold 16 is preferably configured to form at least one variable thickness, rib, groove and/or hole in the component:

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, avant l’étape de consolidation b). 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, before the consolidation step b).

L’image 3f illustre une étape d’emboutissage ou d’estampage. Image 3f illustrates a stamping or embossing step.

Optionnellement, le procédé de fabrication selon l’invention peut inclure une étape de surmoulage, au cours de laquelle le composant 12 est, au moins en partie, surmoulé. L’étape de surmoulage peut être réalisée avec un polymère d’injection de même nature que le polymère utilisé en tant que liant ou matière liante de la plaque de fibres 18 ou de l’empilement 20. Optionally, the manufacturing method according to the invention may include an overmolding step, during which the component 12 is, at least in part, overmolded. The overmolding step may be carried out with an injection polymer of the same nature as the polymer used as a binder or binding material for the fiber plate 18 or the stack 20.

L’étape de surmoulage peut être réalisée lors de l’étape de compression d) ou après l’étape de compression d). The overmolding step can be carried out during compression step d) or after compression step d).

La présente invention apporte plusieurs avantages parmi lesquels : The present invention provides several advantages including:

- une réduction des pertes de matière (notamment de fibres de carbone) durant le cycle de fabrication composite dans le domaine aéronautique, - un recyclage de cette matière pour les composants d’aménagement intérieurs d’un aéronef, comme les sièges d’avion, - a reduction in material losses (particularly carbon fibers) during the composite manufacturing cycle in the aeronautics sector, - recycling of this material for the interior fittings of an aircraft, such as aircraft seats,

- une réduction de la masse des composants d’aménagement intérieurs ainsi obtenus et, par conséquence, une réduction de l’empreinte carbone liée au transport aérien, - etc. - a reduction in the mass of the interior design components thus obtained and, consequently, a reduction in the carbon footprint linked to air transport, - 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 réalisation, au cours de laquelle au moins une couche intissée (14) comportant des chutes de fibres (10) imprégnées avec au moins un liant est réalisée ; b) une étape de consolidation, au cours de laquelle la couche intissée (14) est consolidée, de façon à obtenir au moins une plaque de fibres (18) ; c) une étape de découpe, au cours de laquelle la plaque (18) est découpée ; et optionnellement, une étape de superposition, au cours de laquelle plusieurs plaques de fibres (18) découpées sont superposées et assemblées ensemble, de façon à former un empilement (20) ; et d) une étape de compression, au cours de laquelle la plaque de fibres (18) ou l’empilement (20) est thermocomprimé(e) dans un moule (16), de façon à réaliser un composant (12) ayant une forme non plane. 1. A method of 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 production step, during which at least one non-woven layer (14) comprising fiber scraps (10) impregnated with at least one binder is produced; b) a consolidation step, during which the non-woven layer (14) is consolidated, so as to obtain at least one fiber plate (18); c) a cutting step, during which the plate (18) is cut; and optionally, a superposition step, during which several cut fiber plates (18) are superimposed and assembled together, so as to form a stack (20); and d) a compression step, during which the fiber plate (18) or the stack (20) 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 la plaque de fibres (18) ou l’empilement (20) est chauffé(e) par convection infra-rouge ou céramique. 2. Manufacturing method according to claim 1, in which the fiber plate (18) or the stack (20) is heated by infrared or ceramic convection. 3. Procédé de fabrication selon la revendication 1 ou 2, dans lequel la plaque de fibres (18) et/ou l’empilement (20) est chauffé(e) à une température supérieure ou égale à la température de transition vitreuse ou de fusion du liant. 3. Manufacturing method according to claim 1 or 2, in which the fiber plate (18) and/or the stack (20) is heated to a temperature greater than or equal to the glass transition or melting temperature of the binder. 4. Procédé de fabrication selon l’une quelconques 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. 4. 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. 5. Procédé de fabrication selon l’une quelconques des revendications précédentes, dans lequel le moule (16) est régulé à une température, en particulier à une température inférieure à une température de solidification du liant. 5. Manufacturing method according to any one of the preceding claims, in which the mold (16) is regulated at a temperature, in particular at a temperature below a solidification temperature of the binder. 6. Procédé de fabrication selon l’une quelconques 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 d). 6. 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 d). 7. Procédé de fabrication selon l’une quelconques 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) 7. A manufacturing method according to any one of the preceding claims, wherein the binder is poly(phenylene sulfide) (PPS), polyetherimides (PEI), polyetheretherketone (PEEK), polycarbonate (PC), polyethersulfone (PESU) and/or polyphenylsulfone (PPSU) 8. Procédé de fabrication selon l’une quelconques des revendications précédentes, dans lequel l’étape de compression d) comprend et/ou est suivie par une étape de surmoulage du composant (12). 8. Manufacturing method according to any one of the preceding claims, in which the compression step d) comprises and/or is followed by a step of overmolding the component (12). 9. Procédé de fabrication selon l’une quelconques des revendications précédentes, dans lequel les plaques de fibres (18) découpées et superposées sont assemblées par soudage, notamment ultrason, en particulier par point, les unes aux autres à l’étape de superposition, de façon à ce que l’empilement (20) soit monobloc. 9. Manufacturing method according to any one of the preceding claims, in which the cut and superimposed fiber plates (18) are assembled by welding, in particular ultrasonic, in particular by point, to each other in the superposition step, so that the stack (20) is in one piece. 10. Procédé de fabrication selon l’une quelconques des revendications précédentes, dans lequel lesdites chutes de fibres (10) ont une orientation aléatoire. 10. Manufacturing method according to any one of the preceding claims, in which said fiber scraps (10) have a random orientation. 11. Procédé de fabrication selon l’une quelconques des revendications précédentes, dans lequel le composant est un composant de siège d’un habitacle d’aéronef. 11. Manufacturing method according to any one of the preceding claims, in which the component is a seat component of an aircraft cabin. 12. Procédé de fabrication selon l’une quelconques des revendications précédentes, dans lequel la ou chaque plaque de fibres est découpée à plat à l’étape c) selon des formes correspondant à un développé du composant. 12. Manufacturing method according to any one of the preceding claims, in which the or each fiber plate is cut flat in step c) according to shapes corresponding to a development of the component. 13. Procédé de fabrication selon l’une quelconques des revendications précédentes, dans lequel les plaques de fibres sont assemblées par soudure ultrason à l’étape c), notamment en plusieurs points, de façon à former un empilement d’épaisseur variable et/ou en développée du composant. 13. Manufacturing method according to any one of the preceding claims, in which the fiber plates are assembled by ultrasonic welding in step c), in particular at several points, so as to form a stack of variable thickness and/or in developed form of the component. 14. Procédé de fabrication selon l’une quelconques des revendications précédentes, dans lequel l’empilement est chauffé, embouti et consolidé dans le moule qui est régulé à une température inférieure à la température de solidification du liant. 14. Manufacturing method according to any one of the preceding claims, in which the stack is heated, stamped and consolidated in the mold which is regulated at a temperature lower than the solidification temperature of the binder. 15. 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 quelconques des revendications précédentes. 15. Component (12), in particular for fitting out an aircraft cabin, characterized in that the component (12) is obtained by a manufacturing method according to any one of the preceding claims. 16. Composant (12) selon la revendication précédente, dans lequel le composant est un composant de siège d’un habitacle d’aéronef. 16. Component (12) according to the preceding claim, in which the component is a seat component of an aircraft cabin.
PCT/FR2024/050763 2023-06-16 2024-06-11 Method for manufacturing a component for the outfitting of an aircraft passenger cabin Ceased WO2024256779A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP24738018.1A EP4727758A1 (en) 2023-06-16 2024-06-11 Method for manufacturing a component for the outfitting of an aircraft passenger cabin

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR2306207A FR3149819B1 (en) 2023-06-16 2023-06-16 METHOD FOR MANUFACTURING AN AIRCRAFT CABIN COMPONENT
FRFR2306207 2023-06-16

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WO2024256779A1 true WO2024256779A1 (en) 2024-12-19

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FR (1) FR3149819B1 (en)
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Citations (6)

* 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
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
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
US20210129453A1 (en) 2019-10-31 2021-05-06 GM Global Technology Operations LLC Ultrasonic welding and welding horn having indenter

Patent Citations (6)

* 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
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
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
US20210129453A1 (en) 2019-10-31 2021-05-06 GM Global Technology Operations LLC Ultrasonic welding and welding horn having indenter

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FR3149819A1 (en) 2024-12-20
FR3149819B1 (en) 2025-11-14
EP4727758A1 (en) 2026-04-22

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