Tooling device and method for producing a planar structural component for an aircraft

A tooling device for producing a planar structural component for an aircraft has a moulding tool part with a contour surface for receiving a planar semi-finished product, a heating device for heating the semi-finished product, a film produced from an elastically deformable material and a clamping system with a first clamping device arranged on a first longitudinal side of the contour surface, and a second clamping device arranged on a second longitudinal side of the contour surface located opposite the first longitudinal side. The film is couplable to the clamping devices by the edge regions thereof and, when it is coupled to the clamping devices, covers the contour surface of the moulding tool part. The film is elastically deformable relative to the contour surface by the first and/or the second clamping device to press the semi-finished product in a planar manner against the contour surface for deforming purposes.

FIELD OF THE INVENTION

The present invention relates to a tooling device and to a method for producing a planar structural component for an aircraft.

BACKGROUND OF THE INVENTION

When being assembled, aircraft are composed, in part, from large prefabricated modules. Large structural components which extend in a planar manner are required in particular for constructing the fuselage, for example in order to be able to assemble an outer skin of the aircraft from a few individual parts.

Such planar structural components are usually produced from semi-finished products which are formed from a thermoplastic material. To this end, the semi-finished product is placed between a first moulding tool part, which comprises a first contour surface corresponding to the desired form of the structural components to be produced, and a second moulding tool part, which comprises a second contour surface which is formed in a complementary manner to the first contour surface, and the moulding tool parts are pressed together under the introduction of heat into the semi-finished product in order to deform the semi-finished product thermoplastically to produce the structural component.

BRIEF SUMMARY OF THE INVENTION

Aspects of the present invention may provide an improved concept for producing planar structural components for an aircraft.

According to a first aspect of the invention, a tooling device is provided for producing a planar structural component for an aircraft. The tooling device includes a moulding tool part which comprises a contour surface for receiving a planar semi-finished product, a heating device for heating the planar semi-finished product, a film produced from an elastically deformable material and

a clamping system with a first clamping device, which is arranged on a first longitudinal side of the contour surface of the moulding tool part, and a second clamping device, which is arranged on a second longitudinal side of the contour surface of the moulding tool part located opposite the first longitudinal side. A first edge region of the film is couplable to the first clamping device and a second edge region of the film is couplable to the second clamping device. The film, when it is coupled to the clamping devices, covers the contour surface of the moulding tool part. The film is additionally elastically deformable relative to the contour surface by means of the first and/or the second clamping device in order to press the semi-finished product in a planar manner against the contour surface for deforming purposes.

According to a second aspect of the invention, a method is provided for producing a planar structural component for an aircraft. In this connection, a planar semi-finished product is placed onto a contour surface of a moulding tool part, wherein the semi-finished part is formed from a fibre-reinforced thermoplastic material.

In addition, the semi-finished product is covered with a film produced from an elastically deformable material, wherein the film is coupled to a first clamping device, which is arranged on a first longitudinal side of the contour surface of the moulding tool part, and to a second clamping device, which is arranged on a second longitudinal side of the contour surface of the moulding tool part, wherein the second longitudinal side is located opposite the first longitudinal side. The film

is deformed elastically by means of the clamping devices in such a manner that the semi-finished product is pressed in a planar manner against the contour surface of the moulding tool part. In addition, the semi-finished product is heated to a temperature at which the thermoplastic material is thermoplastically deformable, preferably at the same time as the semi-finished product is pressed against the contour surface by the film. The temperature to which the thermoplastic material is heated can be a temperature within the flow temperature range of the respective thermoplastic material.

One of the ideas of the present invention consists in using a flexible, elastically deformable film for deforming the semi-finished product, by way of which film a semi-finished product placed on the contour surface of the moulding tool part is pressed against the contour surface in order to deform it into the desired form of the structural component. A more uniform pressure distribution is obtained on account of the elasticity of the film than when using a further, rigid moulding tool part. In addition, component tolerances which are produced from the introduction of heat can be compensated for in an efficient manner in this way, such that the structural component is able be produced with improved quality. A further advantage of using an elastic film for deforming the semi-finished product consists in that one and the same film can be used for different dimensioning of the contour surface of the moulding tool part and consequently for producing different component sizes. As a result, the method and the tooling device can be used flexibly, and planar structural components can be produced in an economically efficient manner.

A clamping system which comprises mechanical clamping devices is used according to an embodiment of the invention for deforming the film elastically. The clamping devices are each couplable to edge regions of the film. That is to say, the film is fastened mechanically, for example in a non-positive or positive locking manner, to the clamping devices. In addition, the clamping devices are arranged on oppositely situated sides or laterally of the contour surface so that the film coupled to the clamping device covers the contour surface, preferably completely. The clamping system is set up for the purpose of moving the film into contact with a semi-finished product arranged on the contour surface and thus of pressing the semi-finished product against the contour surface. To this end, the first and/or second clamping devices are set up for the purpose of moving the film in the direction of the contour surface. Clamping devices provide the advantage in this connection that they can be realized in a structurally simple manner and consequently in a cost-efficient manner. In addition, the clamping devices can be realized as components which are separate from the moulding tool part and can easily be exchanged without further changes to the moulding tool, as a result of which the flexibility of the tooling device is increased further.

The method according to an aspect of the invention can be carried out, in particular, by means of the tooling device according to an embodiment of the invention. The features and advantages described in conjunction with the tooling device consequently also apply in an analogous manner to the method and vice versa.

According to an embodiment of the tooling device, it is provided that the first and/or the second clamping device is realized as a clamping roll which is rotatable about a rotational axis which extends along the respective longitudinal side for the elastic deformation of the film. At least one, preferably both of the clamping devices can be realized, in this connection, as a type of roller, on which the film can be wound in order to deform it elastically relative to the contour surface. By the clamping rolls extending along the longitudinal sides of the contour surface, a particularly uniform pressure distribution is obtained along the longitudinal extension of the contour surface during the deforming of the semi-finished product.

According to a further embodiment, the contour surface is convexly curved between the first and the second longitudinal sides.

According to a further embodiment, the contour surface comprises longitudinal recesses for receiving stiffening structures realized on the semi-finished product. On the one hand, this facilitates the positioning of the semi-finished product on the contour surface. Furthermore, the processing of semi-finished products on which stiffening structures are already realized is simplified, in particular, in this manner.

According to a further embodiment, the first and the second longitudinal sides of the contour surface each comprise a length within a range of between 5 metres and 35 metres, in a preferred manner between 10 metres and 35 metres and in a particularly preferred manner between 10 metres and 30 metres. The tooling device is consequently set up, in particular, for the production of large structural components with lengths that are greater than or equal to 5 metres. The use of the elastically deformable film is particularly advantageous in said range of sizes of structural components as said film is able to compensate elastically for changes in the length of the semi-finished product or of the contour surface which occur as a result of the heating process during the production.

According to a further embodiment, the first and the second longitudinal sides are at a distance from one another within a range of between 1.5 metres and 4 metres.

The use of the elastically deformable film is particularly advantageous in said range of sizes of structural components as said film is able to compensate elastically for the changes in length of the semi-finished product or of the contour surface which occur as a result of the heating process during the production.

According to a further embodiment of the tooling device, it is provided that the heating device is realized as a planar heating mat which is dimensioned in such a manner that the contour surface of the moulding tool part is completely coverable with the heating mat. Accordingly, the semi-finished product can be completely covered by the heating mat when the semi-finished product is pressed against the contour surface by the film. Uniform planar heat input into the semi-finished product is consequently obtained.

According to an embodiment, the film is realized from a silicone material. Silicone materials provide the advantage of being mechanically and thermally robust with a high degree of elasticity.

According to an embodiment of the method, it is provided that a first side region of the semi-finished product, which is pressed against the contour surface of the moulding tool in the region of the first longitudinal side, and a second side region of the semi-finished product, which is pressed against the contour surface of the moulding tool in the region of the second longitudinal side, each comprise a length within a range of between 5 metres and 35 metres, in a preferred manner between 10 and 35 metres and in a particularly preferred manner between 10 and 30 metres.

With reference to directional specifications and axes, in particular to directional specifications and axes which refer to the progression of physical structures, a progression of an axis, a direction or a structure “along” another axis, direction or structure is to be understood herein in that they, in particular the tangents produced in a respective position of the structures, extend in each case at an angle of less than 45 degrees, in a preferred manner less than 30 degrees and in a particularly preferred manner parallel to one another.

With reference to the directional specifications and axes, in particular to directional specifications and axes which refer to the progression of physical structures, a progression of an axis, a direction or a structure “transversely” to another axis, direction or structure is to be understood herein in that they, in particular the tangents produced in a respective position of the structures, extend in each case at an angle of more than or equal to 45 degrees, in a preferred manner more than or equal to 60 degrees and in a particularly preferred manner perpendicularly to one another.

A “planar semi-finished product” is deemed herein in general to be a component which extends in a planar manner and is provided for realizing a structural component, in particular a component with a circumferential edge which connects two oppositely oriented main surfaces of the component, the circumferential edge comprising a surface with a negligible surface area compared to a surface area of the main surfaces.

A “fibre-reinforced thermoplastic material”, a “thermoplastic fibre material” or a “thermoplastic fibre-reinforced composite” are to be understood herein in general as a material which is formed from a plurality of, in particular, fibre-shaped or filament-shaped stiffening fibres, such as, for example, carbon, glass, ceramic, aramid, boron, mineral, natural or plastics material fibres or mixtures formed from the same, the stiffening fibres being embedded in a resin or matrix material produced from a thermoplastic synthetic material.

The same reference symbols in the figures designate identical or operationally identical components, in so far as nothing to the contrary is specified.

DETAILED DESCRIPTION

FIG. 4shows a top view of an aircraft3in a schematic manner. The aircraft3comprises a fuselage300which defines a longitudinal axis L3of the aircraft. The fuselage300comprises an outer skin301which is composed of multiple structural components2. The structural components2form outer skin segments and can, depending on the local cross sectional form of the fuselage300, be realized, in particular, as half-shell-shaped components.FIG. 4shows as an example that a top side of the outer skin301of a central fuselage region, with reference to the longitudinal axis L3of the aircraft, is composed of a total of four structural components2. These each comprise, in this connection, a length1within a range of between 5 metres and 35 metres, in particular between 10 metres and 35 metres.

FIGS. 1 to 3show a tooling device1for producing the structural components2. A method for producing the structural components2is also shown inFIGS. 1 and 2.

As shown inFIG. 1as an example, the tooling device1comprises a moulding tool part10, a heating device20, a film30and a clamping system40.

The moulding tool part10comprises a contour surface10a, the surface progression of which corresponds to the form of the structural component2to be produced. The moulding tool part10, shown as an example inFIG. 1, comprises a base part12in the form of a plate-shaped or block-shaped base and a moulded part14on which the contour surface10ais realized. The moulded part14can be fastened, in particular, to the base part12, as an option by means of a releasable connection, such as, for example, screws (not shown) or the like. As a result, different moulded parts14, which each comprise contour surfaces10awith different surface progressions, can be coupled advantageously to the base part12. As an alternative to this, base part12and moulded part14can also be realized in one piece. Generally speaking, the moulded part14juts out from the base part12.

As can be seen inFIG. 3, which shows a top view of the contour surface10a, the contour surface10aextends in a longitudinal direction L1of the tool. In particular, the contour surface10acomprises a first longitudinal side10A, which extends along the longitudinal direction L1of the tool, and a second longitudinal side10B which also extends along the longitudinal direction L1of the tool. The first and the second longitudinal sides10A,10B are placed opposite one another with reference to a transverse direction C1of the tool which extends transversely to the longitudinal direction L1of the tool. The first and the second longitudinal sides10A,10B of the contour surface10acan each comprise a length11,12within a range of between 10 metres and 35 metres along the longitudinal direction L1of the tool. With reference to the transverse direction C1of the tool, the first and the second longitudinal sides10A,10B are preferably arranged at a distance a10from one another within a range of between 1.5 metres and 4 metres. As a result, relatively large, planar structural components2can be produced on the moulding tool part10, as is explained again below in more detail.

As shown as an example inFIG. 1, the contour surface10acan be curved, for example in a convex manner, between the first and the second longitudinal sides10A,10B. Generally speaking, the contour surface10aprotrudes in relation to a base surface12aof the base part12in a vertical direction H1of the tool which extends transversely to the base surface12aor transversely to the longitudinal direction L1of the tool. As is shown additionally inFIG. 2, the contour surface10acomprises optional longitudinal recesses11which extend along the longitudinal direction L1of the tool. As can be seen inFIG. 3, the optional longitudinal recesses11preferably extend over the entire length11,12of the contour surface10a.

As shown schematically inFIG. 1and explained again below, the contour surface10aserves for receiving and deforming a semi-finished product4, from which a structural component2is produced. The optional longitudinal recesses11are provided for receiving stiffening structures5, for example so-called stringers, which are realized on the semi-finished product4.

The film30is dimensioned in such a manner that it is able to cover the contour surface10a, preferably completely. The film30serves for pressing the semi-finished product4or for placing it flatly against the contour surface10a. The film30is formed from an elastically deformable material, for example a silicone material.

As shown schematically inFIG. 1, the clamping system40comprises a first clamping device41and a second clamping device42. The clamping devices41,42are each arranged laterally of the contour surface10awith reference to the transverse direction C1of the tool. The first clamping device41is arranged on the first longitudinal side10A of the contour surface10aof the moulding tool part10. The second clamping device42is arranged on the second longitudinal side10B of the contour surface10b. The clamping devices41,42can be coupled, in particular, to the moulding tool part10, for example fastened to or mounted on said moulding tool part. As shown as an example inFIGS. 1 to 3, the clamping devices41,42can be arranged, in particular, on the base part12. Generally speaking, the clamping devices41,42are arranged in such a manner or can be arranged or moved in such manner that the contour surface10aprotrudes in part in relation to a plane E40, in which the clamping devices41,42are arranged, at least with reference to the vertical direction H1of the tool.

As shown as an example inFIGS. 1 to 3, the clamping devices41,42can each be realized as a clamping roll, which clamping rolls are rotatable in each case about a rotational axis43,44which extends along the respective longitudinal side10A,10B of the contour surface10aor along the longitudinal direction L1of the tool. As shown as an example inFIG. 3, the clamping rolls can each extend along the entire length of the contour surface10a. As can also be seen inFIG. 3, driving devices45,46are preferably provided for rotating the clamping rolls. A first driving device45for driving the first clamping device41and a second driving device46for driving the second clamping device42are provided, as an example, inFIG. 3. The driving devices45,46can be realized, for example, as electric motors.

As can be seen inFIG. 1, the film30can be coupled by way of a first edge region31to the first clamping device41and by way of a second edge region32to the second clamping device42. Eyelets (not shown) can be provided, for example, at the edge regions31,32of the film30, which eyelets, for coupling to the clamping devices41,42, are suspended in hooks (not shown) which are provided on said clamping devices. Other types of coupling, in particular of positive locking or non-positive locking coupling, can obviously also be provided. When the film30is coupled to the clamping devices41,42, the film30covers the contour surface10a, as shown inFIG. 1. The clamping devices41,42are set up for the purpose of moving the film30relative to the contour surface10a, in particular for the purpose of moving the film30in the direction of the contour surface10a. The film30is elastically deformable by means of the clamping devices41,42in order to press the semi-finished product4in a planar manner against the contour surface10afor deforming purposes. For example, the clamping devices41,42, which are realized as clamping rolls, can be rotated for this purpose about the rotational axes thereof41,42so that the film30is wound onto the clamping rolls.

The heating device20serves for heating the planar semi-finished product4. As shown schematically inFIGS. 1 and 2, the heating device20can be realized, in particular, as a planar heating mat21. The heating mat is preferably dimensioned in such a manner that the contour surface10aof the moulding tool part10is fully coverable with the heating mat21, as shown as an example inFIG. 2.

A method for producing the planar structural components2for the aircraft3is explained below as an example with reference to the device described above.

First of all, a planar semi-finished product4is placed onto the contour surface10aof the moulding tool part10, as shown as an example inFIG. 1. The semi-finished product4is formed from a fibre-reinforced thermoplastic material. The semi-finished product4is already preformed in part as an option. The semi-finished product4comprises a first side region4A and a second side region4B which is located opposite said first side region. The first side region4A is placed onto the contour surface10ain the region of the first longitudinal side10A. The second side region4B is placed onto the contour surface10ain the region of the second longitudinal side10B. The side regions4A,4B of the semi-finished product4can each comprise a length with a range of between 5 metres and 35 metres, preferably between 10 metres and 35 metres. The optional stiffening structures5realized on the semi-finished product4are inserted into the optional longitudinal recesses11of the contour surface10a.

As is also shown inFIG. 1, the semi-finished product4is covered by way of the film30. The film30is coupled by way of its first edge region31to the first clamping device41and by way of its second edge region32to the second clamping device42. The film30is then deformed elastically by means of the clamping devices41,42in such a manner that the semi-finished product4is pressed in a planar manner against the contour surface10aof the moulding tool part10. For this purpose, the clamping devices41,42are arranged in such manner or are movable in such a manner that the film30is moved in the direction of the plane E40. For example, one or both of the clamping devices41,42, which are realized as clamping rolls, are rotated about the respective rotational axis43,44thereof, as shown schematically inFIG. 2by the arrows P1and P2. The direction of rotation shown schematically by the arrows P1and P2is, in this case, in such a manner that the film30is welded onto the clamping rolls. As a result, the amount of material of the film30which is located between the clamping devices41,42with reference to the transverse direction C1of the tool is reduced, the part of the film30which is located between the clamping devices41,42is moved in the direction of the plane E40and the film30is placed onto the semi-finished product4. Consequently, the semi-finished product4is pressed firmly against the contour surface10aand, as a result, receives the form provided by the contour surface10a, as shown as an example inFIG. 2. As can be seen inFIG. 2, the first side region4A of the semi-finished product4is pressed against the contour surface10aof the moulding tool10in the region of the first longitudinal side10A and the second side region4B of the semi-finished product4is pressed against the contour surface10aof the moulding tool10in the region of the second longitudinal side10B.

Furthermore, the semi-finished product4is heated by means of the heating device20to a temperature at which the thermoplastic material is thermoplastically deformable. For this purpose, for example, the heating device20, which is realized as a heating mat21, can be placed onto the film30, as is shown schematically inFIG. 2. As an option, the heating mat21can also be placed directly onto the semi-finished product4before it is covered by means of the film30. As a result of heating the thermoplastic material, for example to a temperature within the flow temperature range of the material, said thermoplastic material becomes plastically deformable and, as a result, receives the form of the contour surface10adue to the forces exerted by the film30.

In particular, large, planar structural components2with a length within a range of between 5 and 35 metres can be produced efficiently in this manner. Due to the elasticity of the film30, it is easily possible to compensate for changes in length which arise as a result of the heating process. Furthermore, it is also possible to produce structural components2with different forms with one and the same film30. Deforming the film30elastically by means of a mechanical clamping system provides the tooling device1, in particular, with a structurally simple design.

Although the present invention has been explained above as an example by way of exemplary embodiments, it is not restricted to said exemplary embodiments, but can be modified in a versatile manner. In particular, combinations of the aforementioned exemplary embodiments are also conceivable.

LIST OF REFERENCES

1Tooling device2Structural component3Aircraft4Semi-finished product4A First side region of the semi-finished product4B Second side region of the semi-finished product5Stiffening structures10Moulding tool part10aContour surface10A First longitudinal side of the contour surface10B Second longitudinal side of the contour surface11Longitudinal recesses12Base part12aBase surface14Moulded part20Heating device30Film31First edge region of the film32Second edge region of the film40Clamping system41First clamping device42Second clamping device43Rotational axis of the first clamping device44Rotational axis of the second clamping device45First driving device46Second driving device300Fuselage301Outer skina10Distance between the first and the second longitudinal sidesC1Transverse direction of the toolE40PlaneH1Vertical direction of the tool1Length of the structural componentL1Longitudinal direction of the tool11Length of the first longitudinal side12Length of the second longitudinal sideL3Longitudinal axis of the aircraftP1, P2Arrows