Method of manufacturing a composite structure with prefabricated reinforcement element

Abstract

A method of manufacturing a longitudinally extending composite structure including a shell part comprising a fibre reinforced polymer material including a polymer matrix and fibre material embedded in the polymer material is described. The shell part is manufactured in a closed mould comprising at least a first outer mould part (110) having a first forming surface (112) and a second outer mould part (210) having a second forming surface (212). The method comprises the steps of : a) arranging a first fibre material in the first forming surface of the first outer mould part, b) arranging a pre-fabricated longitudinally extending reinforcement element (130), such as a beam or a web, on top of the first fibre material, the reinforcement element having a first side and a second side, and a first bonding surface and a second bonding surface, the reinforcement element being arranged so that the first bonding surface faces towards the first forming surface, c) arranging a second fibre material (252, 253, 270) in the second forming surface of the second outer mould part ( 210), d) sealing a polymer foil (276) above the second fibre material so as to retain the second fibre material against the second forming surface, e) closing the at least first outer mould part and the second outer mould part so as to form the closed mould, and so that the second bonding surface of the reinforcement element faces towards the second forming surface, f) forming a mould cavity by arranging a first vacuum bag (140) between the first outer mould part, the second outer mould part and the first side of the reinforcement element, and arranging a second vacuum bag (142) between the first outer mould part, the second outer mould part and the second side of the reinforcement element, g) evacuating the mould cavity, h) providing a resin in the mould cavity simultaneously with and/or subsequently to steps a) and c), and i) curing the resin in order to form the composite structure.

Description

technical field [0001] The present invention relates to a method of manufacturing a longitudinally extending composite structure comprising a shell portion comprising a fiber reinforced polymer material comprising a polymer matrix and embedded polymer A fibrous material of the material wherein the housing part is produced in a closed mold comprising at least a first outer mold part having a first forming surface and a second outer mold part having a second forming surface. Background technique [0002] Vacuum infusion or VARTM (Vacuum Assisted Resin Transfer Molding) is a method that is commonly used to manufacture composite structures such as wind turbine blades comprising a fibre-reinforced matrix material. During the manufacturing process, a liquid polymer, also known as resin, is filled into a mold cavity into which fiber material has been inserted beforehand, and a vacuum is created in the mold cavity, which draws in the polymer. Polymers can be thermosets or thermopla...

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Problems solved by technology

[0010] However, the prior art does not address how to ensure that longitudinally extending reinforcement members

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