Dual cure resin composite system and method of manufacturing the same

Abstract

A system including a dual cure composite structure is disclosed. The system also includes a first layer comprising a resin having a first and a second functional group. The system further includes a second layer comprising the resin having the first and the second functional group. The system also includes a third layer comprising the resin having the first and the second functional group. The system further includes a first covalent bond across an interface of the first and the second layer and a second covalent bond across another interface of the second and the third layer. The system further includes more than two layers comprising the resin having the first and second functional group. A method of manufacturing a system including a dual cure composite structure is also disclosed. The method includes providing a first layer comprising a resin having a first functional group and a second functional group. The method also includes applying a first curing source to partially cure the first layer. The method further includes providing a second layer comprising the resin having the first and the second functional group onto the first layer and applying a second curing source to fully cure the first layer and partially cure the second layer simultaneously.

Description

BACKGROUND [0001] The invention relates generally to fabrication techniques and, more particularly, composite fabrication techniques and associated polymer composite-based products. [0002] Structural composite products, such as wind turbine blades and aircraft structures, are composed of multiple layers. The conventional approach for curing these multiple layers involves curing all of the layers together at the same time in an autoclave or oven. In other words, the process involves applying the layers one over the other, and then subsequently curing all of the layers. The adhesion between layers is generally good but other disadvantages sometimes make this approach not practical. For instance, in manufacturing the root section of a wind turbine blades, sagging and dimensional distortion and fiber wrinkling during compaction may occur during curing cycle. Also, excessive reaction exotherm from thick parts may cause problems. Another approach for curing these multiple layers involves ...

AI Technical Summary

Problems solved by technology

The adhesion between layers is generally good but other disadvantages sometimes make this approach not practical.

For instance, in manufacturing the root section of a wind turbine blades, sagging and dimensional distortion and fiber wrinkling during compaction may occur during curing cycle.

Also, excessive reaction exotherm from thick parts may cause problems.

Unfortunately, this fabrication technique creates relatively weak secondary adhesive bonds between the composite layers.

These secondary adhesive bonds result in undesirably low interlaminar strength.

Images