Method for producing a structural section of a vehicle

Abstract

A method for producing a structural section of a vehicle comprises the steps of providing multiple separate skin panels of a fiber-reinforced plastic having an inner side, an outer side and a border running peripherally around the respective skin panel; arranging at least one stiffening component of a fiber-reinforced plastic on each skin panel, on the respective inner side; integrally connecting the respective at least one stiffening component to the skin panels concerned to form a structural component; arranging at least two structural components on a carrier, so that at least regions of the borders of the structural components concerned are in surface-area contact; and integrally connecting the regions of the borders that are in surface-area contact to one another.

Claims

1. A method for producing a structural section of a vehicle, comprising the steps of: providing multiple separate skin panels of a fiber-reinforced plastic having an inner side, an outer side and a border running peripherally around the respective skin panel, arranging at least one stiffening component of a fiber-reinforced plastic on each skin panel, on the respective inner side, integrally connecting the respective at least one stiffening component to the skin panels concerned to form a structural component, arranging at least two structural components on a carrier, so that at least regions of the borders of the skin panels concerned of the structural components are in surface-area contact, integrally connecting the regions of the borders that are in surface-area contact to one another, and compacting and removing the carrier from the connected at least two structural components, wherein the at least one stiffening component is arranged with an offset in relation to the skin panel in such a way that one end of the stiffening component protrudes beyond a border of the skin panel and an opposite end of the stiffening component is at a distance from an opposite border of the skin panel.

2. The method according to claim 1, the step of providing multiple skin panels comprising, for each skin panel, placing at least two layers one on top of the other in a mold and integrally connecting the layers, each layer having a circumferential contour and an offset being formed between the circumferential contours of two layers lying one on top of the other.

3. The method according to claim 1, including wherein the step of arranging at least one stiffening component comprises forming the at least one stiffening component by placing at least two layers, one on top of the other in a mold, subsequently integrally connecting the layers to form the stiffening component, and placing the stiffening component onto the skin panel and subsequently integrally connecting the stiffening component.

4. The method according to claim 3, wherein each layer of the stiffening component has a circumferential contour and an offset being formed between the circumferential contours of two layers lying one on top of the other.

5. The method according to claim 1, further comprising arranging multiple structural components in rows to form individual area segments with an uninterrupted circumference.

6. The method according to claim 1, further comprising arranging the carrier for a defined placing of individual structural components, and successive placing of individual structural components onto the carrier and the respectively subsequent integral connecting of adjacent structural components.

7. The method according to claim 6, wherein at least the placing of the structural components onto the carrier being performed by a multi-axis robot.

8. The method according to claim 1, wherein the fiber-reinforced plastic for providing at least one of the skin panels or the stiffening component comprises a matrix material of a thermoset with reinforcing fibers embedded therein.

9. The method according to claim 8, wherein the integral connecting of two structural components comprises adhesive bonding.

10. The method according to claim 1, wherein the fiber-reinforced plastic for providing at least one of the skin panels or the stiffening component comprises a matrix material of a thermoplastic with reinforcing fibers embedded therein.

11. The method according to claim 10, wherein the integral connecting of structural components comprises welding by at least locally heating a joining zone of the structural components.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features, advantages and application possibilities of the present invention emerge from the following description of the exemplary embodiments and the figures. In these, all of the features described and/or graphically presented form by themselves and in any desired combination the subject matter of the invention, even independently of how they are grouped together in the individual claims or the way in which the claims refer back to one another. Furthermore, in the figures the same designations stand for objects that are the same or similar.

(2) FIGS. 1a to 1c show the structure of a fuselage section with multiple details in various representations.

(3) FIG. 2 shows a fuselage component as a functional unit given by way of example.

(4) FIGS. 3a to 3b show the automated production of a fuselage section.

(5) FIG. 4 shows the possibility of modifying a fuselage by inserting a differing number of additional fuselage sections.

(6) FIG. 5 shows different functional units as a fuselage component.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

(7) FIGS. 1a-c show, by way of example, a skin panel 2, which in this example is produced from multiple layers 4a, 4b and 4c of a thermoplastic, fiber-reinforced material. By way of example and for reasons of simplicity of the representation, for this purpose the three layers 4a, 4b and 4c of identical dimensions lie one on top of the other and are welded to one another. Each of the layers 4a, 4b and 4c has a peripheral circumferential contour 6a, 6b and 6c, which, because of the rectangular shape shown by way of example, is made up here in each case of four edges. The layers 4a, 4b and 4c have a slight offset in relation to one another, so that a stair-shaped structure is formed at a border 8 of the skin panel 2. The border 8 is consequently scarfed.

(8) In FIG. 1b, the skin panel 2 from FIG. 1a is shown, on the inner side 10 of which, by way of example, two stiffening components 12 and 14 are arranged. These are, by way of example, likewise produced from a thermoplastic, fiber-reinforced material. In the representation shown here, both stiffening components 12 and 14 have two flanges 16 and 18 and 20 and 22, with which the stiffening components 12 and 14 are directly in contact and flush with the inner side 10 of the skin panel 2. At these regions, the stiffening components 12 and 14 are welded to the skin panel 2.

(9) The stiffening component 14 has, by way of example, a clearance 24, through which the stiffening component 12 extends. As is evident from the curvature, the stiffening component 14 may be part of a rib, while the stiffening component 12 may be part of a longitudinal stiffening element (stringer). However, the clearance 24 is not absolutely necessary. The stiffening components 12 and 14 may also be jointly produced in such a way as to match one another. For example, both stiffening components 12 and 14 could be integrally produced by an injection-molding technique and have an integral crossing point.

(10) The individual stiffening components 12 and 14 may likewise be produced from multiple layers 26a, 26b and 26c, which are positioned with an offset in relation to one another. This may be realized in a way analogous to the layers 4a, 4b and 4c of the skin panel 2.

(11) Moreover, the stiffening components 12 and 14 are positioned with a slight offset on the inner side 10, so that in each case a region of the stiffening component 12 and 14 protrudes beyond the border 8 of the skin panel 2 or is at a distance from it on the inner side 10. Thus, the stiffening component 12 forms an overhang 28, and a gap 30 on an opposite side of the stiffening component 12. By analogy with this, the stiffening component 14 forms an overhang 32 and, on an opposite side, a gap 34. Overhangs 28 and 32 should be dimensioned to correspond to the respective gap 30 or 34.

(12) The advantages achieved as a result of this are represented in FIG. 1c. The stepped or scarfed configurations of the borders 8 of multiple skin panels 2 may be configured in a way corresponding to one another, so that, by using the stair structure, the borders 8 of two skin panels 2 lie flush one on top of the other. Since fibers respectively extend in the individual layers 4a, 4b and 4c, they can be made to overlap with respectively adjacent layers 4a, 4b and 4c as a result of the stepped design.

(13) Moreover, the overhangs 28 can be used to produce an overlap with an adjacent skin panel 2. The arrangement of the fiber structure and the size of the connecting area can in this way be positively influenced. Consequently, a structural section 37 can be produced from multiple virtually monolithic structural components 36 that are connected to one another.

(14) FIG. 2 shows a larger structural component 38, which can be used as a finished, functional module for producing a structural section. This structural component 38 can extend over a greater surface area than for example the structural component in FIG. 1a. However, here, too, multiple stiffening components 12 and 14 that stiffen the underlying skin panel 2 are provided.

(15) The structural component 38 has, by way of example, cutouts 40 for emergency exits and window cutouts 42. By analogy with the example shown in FIG. 1b, the borders 8 may have a step-like structure. Moreover, a projection 44 and a clearance 46, which are designed to correspond largely to one another, are respectively provided in the plane of the skin panel 2. During the connection to a structural component following in the axial direction (not shown), an overlap can be produced, as already represented in FIG. 1c. A particular advantage lies in the subdivision of a larger structural section into multiple structural components 38, which are easier to produce and to handle. Being made of a fiber-reinforced thermoplastic material also allows a facilitated one-piece type of construction of stiffened regions of the structural component. Furthermore, it is conceivable that the structural component 38 is already made up of multiple structural components 36 from FIGS. 1a to 1c.

(16) FIGS. 3a and 3b schematically show necessary or advantageous devices for automatically carrying out the production of a fuselage section. FIG. 3a first shows a transporting carrier 48, with the aid of which multiple structural components 36 could be transported and temporarily stored. This is only shown by way of example; vertically aligned carriers or holding frames, with which transport between various production units can be carried out, are also conceivable. The structural components 36 stored here may by way of example be gripped by a multi-axis robot 50 with the aid of a gripping tool 52. As represented in FIG. 3a, multiple structural components 36 may be arranged in rows, in order in this way to produce peripheral structural sections 55 of a fuselage 54. These could also be referred to as annular shell sections, circumferential segments or fuselage segments.

(17) The individual structural components 36 are at least locally heated in joining zones, so that the thermoplastic material comprising reinforcing fibers melts and two structural components 36 in contact with one another are integrally connected to one another. The joining region between the structural components 36 may be heated by inductive processes, the use of heating resistors, by transmission or other methods.

(18) For placing the individual structural components 36 in a predefined position, a carrier 56, which is configured as a placement frame and provides multiple holding points 58 on which the individual structural components 36 can be placed, may be used. In particular, the joining zones should be arranged on adjacent holding points 58, so that at least the joining zones lie in a position that is spatially defined very precisely, in order to be connected there to the adjacent parts. It goes without saying that it would also be conceivable to use multiple multi-axis robots 50, which appropriately position multiple structural components 36 simultaneously.

(19) It may also be advantageous to use not only the smaller structural components 36 from FIGS. 1a to 1c but also larger structural components 38, which could be made up of multiple smaller structural components 36.

(20) Apart from facilitated, automatable production and the production of a substantially monolithic fuselage 54 by using a multiplicity of individual structural components 38 that can be easily handled and can be produced in an automated process, the method according to the invention also makes further advantages possible. Represented by way of example in FIG. 4a are three aircraft fuselages 60, 62 and 64, which have identical core dimensions, but differ in length and the outfitting of a middle fuselage section.

(21) The aircraft fuselage 60, for instance, is the shortest of the three aircraft fuselages and merely comprises—at least in this representation—three fuselage barrels 66, 68 and 70. These may have been produced by the method according to the invention, or in some other way. The aircraft fuselage 62 shown vertically in the middle differs from the shorter aircraft fuselage 60 by a lengthening of the middle fuselage barrel 68, by way of example, by altogether six peripheral structural sections 55 comprising structural components 36 adjoining one another. These may have been produced by the method according to the invention and serve for modifying the fuselage 60 to achieve a greater length and a greater number of passenger seats. These additionally inserted shell sections 55 may be designed appropriately for the relevant loads and, to the extent feasible, allow individualization of an aircraft. A further example is shown by the aircraft fuselage 64 lying thereunder, which only comprises two additional peripheral shell sections 55, and consequently has a smaller lengthening. Altogether, the method according to the invention can consequently also be used in addition to other, established methods.

(22) As represented in FIG. 5, an easy individualization of a structural section 72 can also be achieved by the method according to the invention by adaptation of emergency escape hatches 74, arrangement of windows 76 and the like.

(23) It should additionally be pointed out that “having/comprising” does not exclude other elements or steps and “a” or “an” does not exclude more than one. Furthermore, it should be pointed out that features that have been described with reference to one of the above exemplary embodiments can also be used in combination with other features of other exemplary embodiments described above. Designations in the claims should not be regarded as restrictive.

(24) 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.