MANUFACTURING METHOD FOR MANUFACTURING A PROFILE RAIL, PROFILE RAIL OBTAINABLE THEREBY, MOUNTING SYSTEM AND VEHICLE EQUIPPED THEREWITH AND USE OF THE PROFILE RAIL

Abstract

A method for manufacturing a profile rail including a base made of a first material and a top portion to be exposed during use of the profile rail in the floor of a vehicle including a second material that is harder and/or less corrosive as the first material. The method includes the steps of providing the base made of the first material, coating at least the top portion of the base with the second material by a cold spray process, and machining the coating to provide a predefined surface structure of the top portion.

Claims

1. A manufacturing method for manufacturing a profile rail for a floor of a vehicle wherein the profile rail has a base made of a first material and a top portion to be exposed during use of the profile rail in the floor of the vehicle comprising a second material that is at least one of harder or less corrosive than the first material, comprising the steps: a) providing the base made of the first material, and b) coating at least the top portion of the base with the second material by a cold spray process.

2. The manufacturing method according to claim 1, including the further step: c) machining the coating obtained by step b) to provide a predefined surface structure of the top portion.

3. The manufacturing method according to claim 1, wherein step a) comprises at least one or several of the steps: a1) providing the base as a length of a C-, H-, T- or I-profile comprising at least one upper flange to be arranged horizontally in use as the top portion and at least one web to be arranged vertically in use, a2) providing the base made from the first material which is chosen from a group of materials consisting of aluminum, an aluminum alloy, Al7075, Al6061, AlLi2049, Al7136, fiber-reinforced composite material, CFK, fiber reinforced composite material with a thermoplastic matrix, fiber reinforced composite material with a thermosetting matrix, thermoplastic CFK and thermosetting CFK, a3) providing the base with protrusions at a top surface as basis for a seat rail crown to coat the protrusions with the second material in step b), a4) providing the base with oversized holes for generating connector holes in the top portion.

4. The manufacturing method according to claim 3, wherein step b) comprises at least one or several of the following steps: b1) using as the second material one or several metallic materials, especially one or several metallic materials from the group consisting of titanium, titanium alloy, titanium-aluminum alloy, titanium grade 2 (pure titanium), Ti3Al2.5V and Ti6Al4V; b2) using a carrier gas from a group consisting of air, inert gas, noble gas, nitrogen, and helium; b3) conducting the cold spray process with a gas pressure p with 40 barp70 bar, b4) conducting the cold spray process with a gas temperature T with 750 C.T1000 C.; b5) conducting the cold spray process with a powder having particle diameters pd with 25 mpd60 m; b6) applying a bonding layer on a surface area of a base material to be coated and applying the coating by the cold spray process over the bonding layer; b7) coating an upper flange to be used as the top portion in use of the profile rail and an upper part of a web of the profile rail, which web carries the upper flange; b8) providing a bulk mass of the second material on top of the base by the cold spray process such that a seat rail crown with a fastening channel or seat rail crown groove can be formed by machining a bulk mass of second material; b9) coating the top portion of the base provided by step a4) such that the oversized holes are filled or at least coated at their inner surface thereof with the second material; b10) coating the protrusions of the base provided by step a3) with a mass of second material such that a seat rail crown with a fastening channel or seat rail crown groove can be formed by machining the mass of second material.

5. The manufacturing method according to claim 4, wherein step c) comprises at least one or several of the steps: c1) machining the coating for providing a smooth and plane coating surface; c2) providing a hook element made from the second material by machining; c3) machining a seat rail channel or seat rail groove into the second material; c4) boring or drilling the filling of the oversized holes after step b9) such that connector holes with internal cover of second material are achieved; c5) forming a seat rail crown with a fastening channel or seat rail crown groove by machining the mass of second material provided by step b8) or step b9).

6. A profile rail for a floor of a vehicle, obtainable by a manufacturing method according to claim 1, wherein the profile rail comprises a base made of a first material and a top portion to be exposed during use of the profile rail in the floor of the vehicle wherein the top portion comprises a cold sprayed coating of second material that is at least one of harder, more wear-resistant, or less corrosive as the first material.

7. The profile rail according to claim 6, wherein at least one of: the first material is chosen from a group of materials consisting of aluminum, an aluminum alloy, Al7075, Al6061, AlLi2049, Al7136, fiber-reinforced composite material, CFK, fiber reinforced composite material with a thermoplastic matrix, fiber reinforced composite material with a thermosetting matrix, thermoplastic CFK and thermosetting CFK, or the cold sprayed second material is a metallic material chosen from the group consisting of titanium, titanium alloy, titanium-aluminum alloy, titanium grade 2 (pure titanium), Ti3Al2.5V and Ti6Al4V.

8. The profile rail according to claim 6, wherein the base comprises at least one of a length of a C-, H-, T- or I-profile comprising at least one upper flange to be arranged horizontally in use as the top portion and at least one web to be arranged vertically in use; or protrusions at a top surface of the base coated with the second material; holes in the top portion wherein inner surfaces of the holes are coated with cold sprayed second material in order to form connector holes; or a seat rail crown with hook elements made from or at least coated with at least one of the second material, a fastening channel, or a seat rail crown groove made from or at least coated with the second material.

9. A mounting system for objects in a transportation vehicle comprising at least one or several of the profile rails according to claim 6.

10. A floor of a transportation vehicle comprising at least one of the profile rails according to claim 6.

11. A vehicle comprising at least one of the profile rails according to claim 6.

12. At least one of the profile rails according to claim 6 comprising a floor rail in a floor of a vehicle.

13. The at least one of the profile rails according to claim 12, wherein the vehicle comprises an aircraft.

14. At least one of the profile rails according to claim 6 comprising false rails in an aircraft floor.

15. At least one of the profile rails according to claim 6 comprising seat rails in an aircraft floor.

16. At least one of the profile rails according to claim 6 comprising floor panels, partition walls, cabin monuments or passenger seats, in a cabin of an aircraft.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0104] Embodiments of the invention are explained below referring to the accompanying drawings in which:

[0105] FIG. 1 illustrates schematically a step of manufacturing a hybrid profile rail according to a first embodiment wherein a cross section of the hybrid profile rail including a base made from a first material coated at least partially with a second material by a cold spray process and a cold spray apparatus are shown;

[0106] FIG. 2 shows a cross section of the hybrid profile rail after conducting a further step of the manufacturing method;

[0107] FIG. 3 shows a cross section of a hybrid profile rail manufactured by a second embodiment of the manufacturing method;

[0108] FIG. 4 shows a cross section of a base for a hybrid profile rail to be coated by a cold spray process according to a third embodiment of the manufacturing method;

[0109] FIG. 5 shows a cross section of the coated base of FIG. 4 after the cold spray process;

[0110] FIG. 6 shows the finished hybrid profile rail manufactured with the method according to the third embodiment with connecting holes;

[0111] FIG. 7 shows a hybrid profile rail after a cold spray process in a fourth embodiment of the manufacturing method;

[0112] FIG. 8 shows the finished hybrid profile rail manufactured with the method according to the fourth embodiment;

[0113] FIG. 9 shows a cross section of a hybrid profile rail after an intermediate step of the manufacturing method according to a fifth embodiment;

[0114] FIG. 10 shows the cross section of the hybrid profile manufactured with the fifth embodiment of the manufacturing method;

[0115] FIGS. 11 and 12 show cross sections of different variants of bases to be used in the manufacturing method for manufacturing the hybrid profile rail;

[0116] FIG. 13 shows a side view of a first example of a vehicle with a floor in which profile rails manufactured with a method according to an embodiment of the invention is used; and

[0117] FIG. 14 shows a partly broken away top view of a second example of a vehicle with a floor in which profile rails manufactured with a method according to an embodiment of the invention is used.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0118] In the following preferred embodiments of a manufacturing method for manufacturing a profile rail 10 for a floor 62 of a vehicle 58, such as a passenger cabin floor of an aircraft 60, are explained in more detail with reference to the accompanying drawings.

[0119] The profile rail 10 is a hybrid profile rail made from different materials 12, 14. The profile rail 10 has a base 16 made of a first material 12 and a top portion 18 to be exposed during use of the profile rail 10 in the floor 62 of the vehicle 58 wherein the top portion 18 comprises a second material 14 that is harder and/or less corrosive as the first material 12.

[0120] The manufacturing method comprises the steps: [0121] a) providing the base 16 made of the first material 12 and [0122] b) coating at least the top portion 18 of the base 16 with the second material 14 by a cold spray process.

[0123] Preferably, the manufacturing method comprises the further step: [0124] c) machining the coating 32 obtained by step b) in order to provide a predefined surface structure of the top portion 18.

[0125] Referring to all of the Figures, the base 16 is a length of a profile element or baseline rail section 20 made from the first material 12. The base 16 may have different cross sections, wherein an I-profile or a H-profileas depicted in the FIGS. 1 to 10 is preferred. As shown in FIGS. 11, and 12, other cross sections such as a T-profile or a C- or U-profile, Z-profile, S-profile, . . . are possible.

[0126] According to the embodiments shown in FIGS. 1 to 10 and 12, the base 16 has an upper flange 22, a lower flange 24 and a web 26 connecting the upper and lower flanges 22, 24. As shown in FIG. 11, the lower flange 24 may be omitted.

[0127] The first material 12 is a lightweight material, preferably a cost-effective material. Preferably, the first material is aluminum, especially an aluminum alloy such as Al7075, Al6061, AlLi2049 or Al7136. In other embodiments the first material 12 can be fiber-reinforced composite material such as CFK 56, especially fiber reinforced composite material with a thermoplastic matrix or fiber reinforced composite material with a thermosetting matrix such as thermoplastic CFK and thermosetting CFK, respectively. The manufacturing method as well as the hybrid profile rail 10 manufactured therewith is explained in more detail, by way of example only, with an aluminum base 16.

[0128] In use, the upper flange 22 is exposed and would be prone to wear and/or corrosion. Therefore at least the exposed surface of the upper flange 22 is coated with the second material 14 as protection against corrosion and/or wear.

[0129] Preferably, the second material 14 is a metallic material. Most preferred the second material 14 is titanium, especially titanium grade 2 (pure titanium) or a titanium alloy, preferably a titanium-aluminum alloy such as Ti3Al2.5V or Ti6Al4V.

[0130] Referring to FIG. 1, the top portion 18 of the base 16 including the upper flange 22 and a part of the web 26 is coated with the second material 14 by the cold spray process. A cold spray apparatus 28 for conducting the cold spray process is shown very schematically, and not in scale with the profile rail 10.

[0131] During the Cold Spray process a metal powder is blasted with supersonic velocity onto a target substratehere the base 16.

[0132] Referring to FIG. 1, a proposed hybrid material False Rail 29example of the profile rail 10is based on an aluminum baseline rail, preferable in I-shapeexample of the base 16. A false rail 29 is for example used in passenger cabin floors and has a flat upper surface which connects different floor panels of the cabin.

[0133] Onto this baseline rail as base 16 titanium powder 30 is sprayed with the Cold Spray process. This results in a mechanical welding of the powder particles with the aluminum baseline rail and then with each other.

[0134] More generally, the cold spray apparatus 28 is configured to apply the coating 32 of the second material 14 onto at least one surface of the top portion 18 by conducting the cold spray process.

[0135] The cold spray apparatus 28 comprises a scanning device 33, such as a robotic arm 34, adapted and configured to scan the surface area to be coated and equipped with a cold spray head 36 as generally known, for example from [11] to [15], incorporated herein by reference.

[0136] The Cold Spray process comprises the following steps: [0137] Mixing the powder 30 of second material 14 with gas (Air, inert gas, N2, noble gas or He) [0138] Powder particles are accelerated by the jet of gas up to supersonic speed [0139] Powder particles remain in solid state during spraying [0140] Cold Spray rely only on plastic deformation to build up coatings

[0141] Preferably, the cold spray process is conducted with the following parameters: [0142] Carrier gas: He or N2 preferred [0143] Gas pressure p: 40 bar to 70 bar [0144] Gas temperature T: 750 C. to 1100 C. [0145] Particle size: 25 m to 60 m.

[0146] Referring to FIG. 2, this surface coating 32 can be machined later into the final surface quality. The surface coating 32 with titanium powder 30 is preferably extended around the edges of the upper I-flanges 22 and extends up to the middle of the vertical web 26.

[0147] This added titanium layer onto the aluminum baseline rail represents a corrosion resistant material. Special, sometimes hazardous, surface treatments needed for aluminum rails can be omitted.

[0148] With a coating 32 extending down to the vertical web area the risk for corrosion at the direct contact surface between aluminum and titanium can be significantly reduced as fluids can evaporate in this area.

[0149] In specific areas of the aircraft floor, so called wet areas, a high corrosion risk is present. In order to withstand this corrosion risk usually False Rails machined completely in titanium are used. These titanium False Rails are significantly more expensive than aluminum False Rails. Therefore, this combination of an aluminum baseline rail with a Cold Spray applied titanium coating 32 offers a cost-effective alternative.

[0150] In other embodiments (not shown) the whole base 16 is coated or only a part of the upper flange 22, for example the top surface and the sides of the upper flange 22. More generally, at least a part of the profile rail 10 which is exposed so that a risk of wear or corrosion may arise is coated with the cold spray process.

[0151] FIG. 1 shows a standard false rail 29 section as example for the profile rail 10 including the base 16 made from aluminum as an example for the first material 12 and the coating 32 made by cold spraying using titanium powder 30 as an example for the second material 14. FIG. 1 shows the situation with the cold spray titanium as sprayed. FIG. 2 shows the finished false rail section after a machining step with the cold sprayed titanium machined. The machining step may comprise typical machining process steps such as cutting, grinding, boring, drilling, milling, broaching, sawing, shaping, planning, reaming, lapping and tapping, see [16] for more details.

[0152] FIG. 3 shows a cross section of the profile rail 10 manufactured by a second embodiment of the manufacturing process. Here, the cold spray process comprises coating the top portion 18 with a bonding layer 38 first and then applying the second material 14 onto the bonding layer. When, for example, the more resistant and harder alloys Ti3Al2.5V or Ti6Al4V are used as the second material 14, it is preferable to use the softer Ti Grade2 as material for the bonding layer 38. More generally, the material of the bonding layer is used such that bonding of the first material 12 and the second material 14 is enhanced. The bonding layer 38 may also be applied by cold spraying (CS). The material of the bonding layer 38 can be chosen in accordance with the choice of the first and second materials 12, 14, especially in order to enhance bonding between the first and second materials 12, 14. While the bonding layer 38 is shown only in the embodiment of FIG. 3, it can be used in the other embodiments as well.

[0153] FIG. 4 to 6 illustrate a third embodiment of the manufacturing process which is similar to the embodiment of FIGS. 1 and 2, but which is adapted for a manufacturing of a false rail 29 section with connector holes 40. Referring to FIG. 4, a false rail 29 baseline section made from aluminum as the first material 12 is provided as the base 16, wherein oversized holes 42 for connectors are provided in the upper flange 22. FIG. 5 shows the situation after the cold spraying. The top portion 18 is coated with titanium as the second material 14, and this second material 14 also fills the oversized holes 42. FIG. 6 shows the situation after the machining step which includes a step of generating, e.g., drilling, the connector holes 40 through the oversized holes 42 filled with titanium. Thus, the profile rail 10 is provided with connector holes 40 with an internal titanium cover.

[0154] FIGS. 7 to 10 show further embodiments of the manufacturing process for manufacturing profile rails 10 in the form of hybrid seat rails 43 having a seat rail crown 44. The seat rail crown 44 has hook elements 45 defining a fastening channel in form or a seat rail crown groove 52 (dovetail slot). Different shapes of seat crowns as such are generally known, please see [1] to [10]. According to the embodiments shown, the seat rail crown 44 may be made fully from the second material 14 as this is shown in FIGS. 7 and 8, or the base 16 may be provided with protrusions 46 which form rudimentary seat crown bases 48 as shown in FIGS. 9 and 10.

[0155] FIG. 7 shows the situation after the cold spray process before machining. The second material 14 (e.g., titanium) is applied in several layers by cold spraying until a bulk mass 50 of second material 14 is formed on top of the base 16. FIG. 8 shows the situation after machining, where the seat rail crown 44 is machined into the bulk mass 50 of second material 14. The seat rail crown 44 is fully made from second material 14.

[0156] As shown in FIGS. 9 and 10, an amount of second material 14 can be saved when at least an inner part of the seat rail crown 44 is made from the first material 12. FIG. 9 shows the situation after cold spraying and a first machining step. FIG. 10 shows the finished seat rail 43as example of the hybrid profile rail 10after a second machining process where a seat rail crown groove 52here shaped as a dovetail slotis machined into the second material 14 between the protrusions 46.

[0157] Hence, referring to the embodiments of FIGS. 7 to 10, the proposal explained above on the example of a false rail 29 as profile rail 10 can be extended towards the creation of a hybrid seat rail 43 profile as a further example of the profile rail 10. The hybrid material seat rail 43 is based on an aluminum baseline rail as base 16, preferable in I-shape. Alternatively, an I-shape baseline rail with rudimental crown-flangesexample for protrusions 46can be used.

[0158] Onto this baseline rail, i.e., the base 16, titanium powder 30 is sprayed with the Cold Spray process. This results in a mechanical welding of the powder particles with the baseline rail and then with each other. Due to this several layers of titanium can be aggregated onto the baseline rail until a sufficient amount is reached. This amount can be machined later into the final desired seat rail-crown design. The surface coating 32 with titanium powder 30 is preferably extended around the edges of the upper I-flange 22 carrying the crown 44 and extends up to the middle of the vertical web 26.

[0159] This added titanium layer onto the aluminum baseline rail represents a corrosion resistant material. Special, sometimes hazardous, surface treatments needed for aluminum seat rails can be omitted.

[0160] With a coating 32 extending down to the vertical web 26 area the risk for corrosion at the direct contact surface between aluminum and titanium can be significantly reduced as fluids can evaporate in this area.

[0161] In specific areas of the aircraft floor, so called wet areas, a high corrosion risk is present. In order to withstand this corrosion risk usually seat rail machined completely in titanium are used. These titanium seat rails are significantly more expensive than aluminum seat rails. Therefore, the combination of an aluminum baseline rail in with a cold spray applied titanium crown 44 according to the embodiments of FIGS. 7 to 10 offers a cost-effective alternative.

[0162] As shown in FIGS. 11 and 12, different baseline rail sections made from different first materials including CFK 56 can be used as base 16 to be coated at least partially with the wear- and/or corrosive-resistance second material 14. While corrosion is not an issue with CFK 56, the coating with a harder metal enhances resistance against wear and scratches.

[0163] The hybrid profile rail 10 can be used in floors 62 of vehicles 58, examples of which are shown in FIGS. 13 and 14. Further examples are shown and described in [1] to [10], incorporated herein by reference. Especially, the profile rail 10 can be used as false rails 29, as seat rails 43 and/or in a mounting system 68 for mounting objects 64, floor panels of false floors, seats, cabin monuments, partition walls, . . . in a cabin 66 of an aircraft 60.

[0164] In order to provide an enhanced wear and corrosion resistant hybrid profile rail (10) to be used in floors (62) of vehicles (58) such as aircraft (60), a new manufacturing method is proposed for manufacturing the profile rail (10) that comprises a base (16) made of a first material (12) and a top portion (18) to be exposed during use of the profile rail (10) in the floor (62) of the vehicle (58) comprising a second material (14) that is harder and/or less corrosive as the first material (12). The method comprises the steps: [0165] a) providing the base (16) made of the first material (12) and [0166] b) coating at least the top portion (18) of the base (16) with the second material (14) by a cold spray process, and preferably [0167] c) machining the coating (32) obtained by step b) in order to provide a predefined surface structure of the top portion (18).

[0168] While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms comprise or comprising do not exclude other elements or steps, the terms a or one do not exclude a plural number, and the term or means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.

REFERENCE SIGN LIST

[0169] 10 profile rail [0170] 12 first material [0171] 14 second material [0172] 16 base [0173] 18 top portion [0174] 20 baseline rail section [0175] 22 upper flange [0176] 24 lower flange [0177] 26 web [0178] 28 cold spray apparatus [0179] 29 false rail [0180] 30 powder [0181] 32 coating [0182] 33 scanning device [0183] 34 robotic arm [0184] 36 cold spray head [0185] 38 bonding layer [0186] 40 connector hole [0187] 42 oversized hole [0188] 43 seat rail [0189] 44 seat rail crown [0190] 45 hook element [0191] 46 protrusion [0192] 48 seat crown base [0193] 50 bulk mass [0194] 52 seat rail crown groove [0195] 56 CFK [0196] 58 vehicle [0197] 60 aircraft [0198] 62 floor [0199] 64 object [0200] 66 (passenger) cabin [0201] 68 mounting system