Abstract: A device for forming a composite laminate (10) for obtaining a Z-shaped profile (1) including: a grip module (5) comprising two plates (6) configured to enclose and grip between the two plates (6) a first portion of the composite laminate (10) that will form a first flange (3), and a feed module (7) comprising two plates (8) configured to enclose between the two plates (8) a second portion of the composite laminate (10), wherein the feed module (7) is configured to heat the portion of the composite laminate (10) located between its two plates (8) and to be movable with respect to the grip module (5) parallel to the plane of the web (2) of the composite profile (1) once formed to a second position in which the two plates (8) enclose the portion of the composite laminate (10) that will form a second flange (4).

Abstract: A method for manufacturing a composite assembly with a continuous skin for a rear end of an aircraft by obtaining an upper part of the rear end by composite tooling. The upper part comprises a multi-spar vertical tail plane. The spars of the vertical tail plane comprise widening roots that form an upper shell of the rear end and an upper skin. Furthermore, a lower part comprises a lower shell of the rear end including semi-complete frames and stringers and a lower skin. The upper and lower parts are assembled with a joining procedure. The upper and lower skins are joined to obtain the composite assembly with the continuous skin.

Abstract: A method for manufacturing an aircraft rear section including a tail cone and a vertical tail plane, the method includes: providing pre-cured frames (1) each of which includes a section of the tail cone (2) and a section of the vertical tail plane (3); providing pre-cured stringers (4); placing the pre-cured stringers (4) each in respective positions within the pre-cured frames (1); placing a skin (5) around an external surface of the pre-cured frames (1); and curing the pre-cured frames (1), the pre-cured stringers (4), and the skin (5), forming the final aircraft rear section.

Abstract: A method for manufacturing a composite assembly of an empennage and rear-fuselage having a continuous skin solution. The method obtains parts of the sub-structure. For each part, it is obtained a plurality of stringers performs and frames preforms by composite tooling. The frames are transferred to curing frames molds and a sub-structure skin is obtained. Furthermore, the method includes integrating the parts over an integration tool having cavities for locating the curing frames molds and the stringer performs. Furthermore, the method includes co-curing the integration tool in one shot on an autoclave, demolding the sub-structure skin sections and disassembling the curing frame molds to obtain the composite assembly of the rear section.

Abstract: A method for manufacturing a composite rear section assembly having a continuous skin solution including obtaining a vertical tail plane tooling that has intermediate tooling for tooling intermediate preforms of a vertical tail plane (800), obtaining a fuselage barrel tooling (420a), (420b), (420c) and (420d) the fuselage barrel tooling having a cut-out (503a), (503b), (503c) and longitudinal cavities (501a), (501b), (501c) and (501d), attaching the vertical tail plane tooling to the fuselage barrel tooling by the cut-out of the fuselage barrel tooling, performing a composite skin lay-up (801) over the fuselage barrel tooling and the vertical tail plane tooling to obtain a continuous skin, curing the composite skin lay-up, the vertical tail plane tooling and the fuselage barrel tooling and demolding the tools to obtain the composite assembly with a continuous skin (1300), (1600).

Abstract: A device for forming a composite laminate (10) for obtaining a Z-shaped profile (1) including: a grip module (5) comprising two plates (6) configured to enclose and grip between the two plates (6) a first portion of the composite laminate (10) that will form a first flange (3), and a feed module (7) comprising two plates (8) configured to enclose between the two plates (8) a second portion of the composite laminate (10), wherein the feed module (7) is configured to heat the portion of the composite laminate (10) located between its two plates (8) and to be movable with respect to the grip module (5) parallel to the plane of the web (2) of the composite profile (1) once formed to a second position in which the two plates (8) enclose the portion of the composite laminate (10) that will form a second flange (4).

Abstract: A method to integrate a first part and a second part comprising composite material, both parts being at least partially thermoplastic parts, that comprises the steps of providing the first part, placing the first part in a tool, applying an in-situ consolidation process, such that integration layers of thermoplastic material are laid on thermoplastic plies of the first part and the integration of the first part with the integration layers is obtained, the integration layers being the first layers of the second part, wherein the applied in-situ consolidation process comprises the sub-steps of melting each tape by a heat source, and welding to the layer below, compressing by a roller, and cooling down below melting temperature of thermoplastic, laying the rest of the second part, and curing or consolidation of a remainder of the second part.

Abstract: A method for manufacturing a composite rear section assembly having a continuous skin solution including obtaining a vertical tail plane tooling that has intermediate tooling for tooling intermediate preforms of a vertical tail plane (800), obtaining a fuselage barrel tooling (420a), (420b), (420c) and (420d) the fuselage barrel tooling having a cut-out (503a), (503b), (503c) and longitudinal cavities (501a), (501b), (501c) and (501d), attaching the vertical tail plane tooling to the fuselage barrel tooling by the cut-out of the fuselage barrel tooling, performing a composite skin lay-up (801) over the fuselage barrel tooling and the vertical tail plane tooling to obtain a continuous skin, curing the composite skin lay-up, the vertical tail plane tooling and the fuselage barrel tooling and demolding the tools to obtain the composite assembly with a continuous skin (1300), (1600).

Abstract: A method for manufacturing a composite assembly of an empennage and rear-fuselage having a continuous skin solution. The method obtains parts of the sub-structure. For each part, it is obtained a plurality of stringers performs and frames preforms by composite tooling. The frames are transferred to curing frames molds and a sub-structure skin is obtained. Furthermore, the method includes integrating the parts over an integration tool having cavities for locating the curing frames molds and the stringer performs. Furthermore, the method includes co-curing the integration tool in one shot on an autoclave, demolding the sub-structure skin sections and disassembling the curing frame molds to obtain the composite assembly of the rear section.

Abstract: A method for manufacturing a composite assembly with a continuous skin for a rear end of an aircraft by obtaining an upper part of the rear end by composite tooling. The upper part comprises a multi-spar vertical tail plane. The spars of the vertical tail plane comprise widening roots that form an upper shell of the rear end and an upper skin. Furthermore, a lower part comprises a lower shell of the rear end including semi-complete frames and stringers and a lower skin. The upper and lower parts are assembled with a joining procedure. The upper and lower skins are joined to obtain the composite assembly with the continuous skin.

Abstract: A method for manufacturing an aircraft rear section including a tail cone and a vertical tail plane, the method includes: providing pre-cured frames (1) each of which includes a section of the tail cone (2) and a section of the vertical tail plane (3); providing pre-cured stringers (4); placing the pre-cured stringers (4) each in respective positions within the pre-cured frames (1); placing a skin (5) around an external surface of the pre-cured frames (1); and curing the pre-cured frames (1), the pre-cured stringers (4), and the skin (5), forming the final aircraft rear section.

Abstract: A joining method for thermoplastic elements that comprises the steps of providing two thermoplastic parts having two surfaces to be joined, locating a graphene layer between the two thermoplastic parts adjacent to the surfaces to be joined, and heating the graphene layer such that the graphene layer melts the thermoplastic resin of the adjacent surfaces of the two thermoplastic parts that are to be joined.

Abstract: The present disclosure refers to the manufacturing process of an aperture surrounding frame for an aircraft fuselage. The method includes providing a tubular braiding material (2) with a perimeter equal to the perimeter of the frame to be manufactured, cutting the tubular braiding material (2) to obtain annular-shaped braiding slices (3), providing an annular-shaped inner mold (4) where the annular-shaped inner mold has a surface with a desired shape for the aperture surrounding frame, layering up at least one braiding slice (3) around the inner mold (4), forming the at least one braiding slice (3) around the inner mold (4), and curing the aperture surrounding frame pre-form. The present disclosure also refers to an aperture surrounding frame (1) for an aircraft fuselage formed as a continuous body by at least one annular-shaped braiding slice (3) with a perimeter equal to the perimeter of the desired aperture surrounding frame.

Abstract: The present disclosure refers to the manufacturing process of an aperture surrounding frame for an aircraft fuselage. The method includes providing a tubular braiding material (2) with a perimeter equal to the perimeter of the frame to be manufactured, cutting the tubular braiding material (2) to obtain annular-shaped braiding slices (3), providing an annular-shaped inner mold (4) where the annular-shaped inner mold has a surface with a desired shape for the aperture surrounding frame, layering up at least one braiding slice (3) around the inner mold (4), forming the at least one braiding slice (3) around the inner mold (4), and curing the aperture surrounding frame pre-form. The present disclosure also refers to an aperture surrounding frame (1) for an aircraft fuselage formed as a continuous body by at least one annular-shaped braiding slice (3) with a perimeter equal to the perimeter of the desired aperture surrounding frame.

Abstract: An injection interface device comprising a wedge having a first surface mountable over the joint between the mold and the terminal element and a second surface being inclined with respect to the first surface. A fixation element is mountable against the second surface and an attachment element. The device is configured so that it avoids or prevents the movement of the wedge in a direction parallel to the mold and the movement of the fixation element in a direction perpendicular to the mold so that a displacement of the fixation element parallel to the mold makes a displacement of the wedge in a direction perpendicular to the mold so that the wedge presses against the terminal element to seal it.

Abstract: An injection interface device comprising a wedge having a first surface mountable over the joint between the mold and the terminal element and a second surface being inclined with respect to the first surface. A fixation element is mountable against the second surface and an attachment element. The device is configured so that it avoids or prevents the movement of the wedge in a direction parallel to the mold and the movement of the fixation element in a direction perpendicular to the mold so that a displacement of the fixation element parallel to the mold makes a displacement of the wedge in a direction perpendicular to the mold so that the wedge presses against the terminal element to seal it.

Abstract: Composite aircraft frame (1) comprising two segments (10, 20), each of these segments (10, 20) being single unitary element made in composite material and comprising at least one web (2), a stiffening structure and a fitting (4), the two segments (10, 20) being joint by the fittings (4) using rivets, forming the aircraft frame (1). The invention also refers to a method for fabricating such an aircraft frame (1).

Abstract: Composite aircraft frame (1) comprising two segments (10, 20), each of these segments (10, 20) being single unitary element made in composite material and comprising at least one web (2), a stiffening structure and a fitting (4), the two segments (10, 20) being joint by the fittings (4) using rivets, forming the aircraft frame (1). The invention also refers to a method for fabricating such an aircraft frame (1).