Method and system for forming a fiber reinforced polymer component

Abstract

The present disclosure relates to a method for forming a fiber-reinforced polymer member. The method includes impregnating a first fiber bundle with a polymerizable liquid contained in a reservoir to form a first impregnated fiber bundle. The method also includes positioning the first impregnated fiber bundle within a build region of the reservoir. The build region has a shape and size corresponding to a cross-sectional shape of the fiber-reinforced polymer member. Further, the method includes irradiating the build region of the reservoir to form a polymerized solid from the polymerizable liquid within the build region. The polymerized solid encloses a portion of the first fiber bundle to form at least a portion of the fiber-reinforced polymer member.

Description

Technical Field

[0001] This disclosure generally relates to fiber-reinforced polymer components. More particularly, this disclosure relates to methods and systems for forming fiber-reinforced polymer components, such as those used in wind turbines. Background Technology

[0002] Wind power is considered one of the cleanest and most environmentally friendly energy sources available today, and wind turbines are receiving increasing attention in this area. A modern wind turbine typically consists of a tower, a nacelle mounted on the tower, a generator positioned within the nacelle, and one or more rotor blades. These rotor blades use the known airfoil principle to convert the kinetic energy of the wind into mechanical energy. A drive system transfers the mechanical energy from the rotor blades to the generator. The generator then converts the mechanical energy into electrical energy, which can be supplied to the public power grid.

[0003] Certain components of wind turbines (such as shear webs or other parts of rotor blades) may have complex geometries that can be optimally formed using suitable additive manufacturing processes. In many such additive manufacturing processes, bulk liquefied thermoplastic is deposited at various desired locations to form component layers. Once this layer has cured, additional liquefied thermoplastic is deposited at various locations on top of it to form subsequent layers. This process is repeated until a complete component is formed. Reinforcing fibers can be added as needed. However, this type of additive manufacturing process is generally time-consuming and requires long cycle times.

[0004] Recently, continuous additive manufacturing processes have been developed in which each layer is formed simultaneously. These continuous additive manufacturing processes generally require shorter cycle times than additive manufacturing processes in which material is deposited one drop at a time. However, current continuous additive manufacturing processes cannot incorporate reinforcing fibers, which are essential for forming fiber-reinforced polymer components, such as those used in wind turbines.

[0005] Therefore, improved methods and systems for the continuous formation of fiber-reinforced polymer components will be welcomed in the art. Summary of the Invention

[0006] The technical aspects and advantages will be set forth in part in the following description, or may be apparent from the description, or may be learned by implementing the technology.

[0007] In one aspect, this disclosure relates to a method for forming a fiber-reinforced polymer component. The method includes impregnating a first fiber bundle with a polymerizable liquid contained in a reservoir to form a first impregnated fiber bundle. The method further includes positioning the first impregnated fiber bundle within a build region of the reservoir. The build region has a shape and dimensions corresponding to the cross-sectional shape of the fiber-reinforced polymer component. Furthermore, the method includes irradiating the build region of the reservoir to form a polymeric solid within the build region from the polymerizable liquid. The polymeric solid surrounds a portion of the first fiber bundle to form at least a portion of the fiber-reinforced polymer component.

[0008] In another aspect, this disclosure relates to a method for forming a lattice portion of a continuous fiber-reinforced polymer wind turbine component. The method includes impregnating a first fiber bundle and a second fiber bundle with a polymerizable liquid contained in a reservoir to form a first impregnated fiber bundle and a second impregnated fiber bundle. The method further includes positioning the first and second impregnated fiber bundles within a build region of the reservoir, wherein the first fiber bundle is positioned at a different location within the build region than the second fiber bundle. The build region has a shape and dimensions corresponding to the cross-section of the lattice portion of the fiber-reinforced polymer wind turbine component. The method further includes irradiating the build region of the reservoir to form a polymeric solid within the build region from the polymerizable liquid. The polymeric solid is attached to a build plate and surrounds a portion of the first and second fiber bundles to form at least a portion of the lattice portion of the fiber-reinforced polymer wind turbine component. Additionally, the method includes continuously moving the build plate away from the build region while irradiating the build region. Furthermore, the method includes adjusting at least one of the shape or dimensions of the build region when the cross-section of the lattice portion of the fiber-reinforced polymer wind turbine is forced to change.

[0009] In another aspect, this disclosure relates to a system for forming fiber-reinforced polymer components. The system includes a reservoir containing a polymerizable liquid. The reservoir includes a build region having a shape and dimensions corresponding to the cross-section of the fiber-reinforced polymer component. The reservoir also includes a dead zone positioned between a bottom wall of the reservoir and the build region. The dead zone contains oxygen to prevent polymerization of the polymerizable liquid. The system also includes a mirror configured to direct radiation into the build region of the reservoir. The radiation forms a polymeric solid from the polymerizable liquid within the build region. The system also includes a guiding tool positioned within the dead zone of the reservoir. The guiding tool is configured to position an impregnated fiber bundle within the build region of the reservoir. Additionally, the system includes a controller communicatively coupled to the mirror and the guiding tool. The controller is configured to control the guiding tool to position the impregnated fiber bundle within the build region of the reservoir. The controller is also configured to control the mirror to irradiate the build region of the reservoir.

[0010] These and other features, aspects, and advantages of the present technology will become more readily understood with reference to the following description and the appended claims. Embodiments of the technology are illustrated in conjunction with the accompanying drawings, which are incorporated in and form part of this specification, and together with the description, serve to explain the principles of the technology. Attached Figure Description

[0011] The complete and enabling disclosure of the present invention (including its best mode) to those skilled in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0012] Figure 1 This is a perspective view of an exemplary wind turbine according to aspects of this disclosure;

[0013] Figure 2 This is a perspective view of an exemplary rotor blade according to aspects of this disclosure;

[0014] Figure 3 It is generally about Figure 2 The cross-sectional view of the rotor blade shown by line 3-3 illustrates the shear web located within the rotor blade according to aspects of this disclosure.

[0015] Figure 4 This is a perspective view of one embodiment of a shear web according to aspects of this disclosure;

[0016] Figure 5 This is a perspective view of one embodiment of the internal lattice structure of the shear web according to aspects of this disclosure;

[0017] Figure 6 This is a schematic diagram of one embodiment of a system for forming fiber-reinforced polymer components according to aspects of this disclosure;

[0018] Figure 7 It is used to form Figure 4 An enlarged schematic diagram of a portion of a fiber-reinforced polymer component system is shown, illustrating dead zones and build-up areas within a reservoir filled with a polymerizable liquid;

[0019] Figure 8 The bottom view of the polymer solid according to an aspect of this disclosure shows a plurality of guiding tools configured to position a plurality of fiber bundles within a build area;

[0020] Figure 9 This is a top view of an embodiment of a guide tool according to aspects of this disclosure; and

[0021] Figure 10 This is a flowchart illustrating an embodiment of a method for forming fiber-reinforced polymer components, according to aspects of this disclosure.

[0022] The repeated use of reference symbols in this specification and figures is intended to indicate the same or similar features or elements of the art. Detailed Implementation

[0023] Referring now to this embodiment of the technology, one or more examples of which are shown in the accompanying drawings. Detailed descriptions use numerical and alphabetic designations to indicate features in the figures. Similar or analogous designations in the figures and descriptions are used to indicate similar or analogous parts of the technology. As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of a single component.

[0024] Each example is provided as an explanation of the technology and is not intended to limit it. Indeed, it will be apparent to those skilled in the art that modifications and variations can be made to this technology without departing from its scope or spirit. For example, a feature shown or described as a part of one embodiment may be used in another embodiment to produce further embodiments. Therefore, it is intended that this technology cover such modifications and variations as falling within the scope of the appended claims and their equivalents.

[0025] Now refer to the diagram. Figure 1 A perspective view of one embodiment of an exemplary wind turbine 10 according to this disclosure is shown. As shown, the wind turbine 10 generally includes a tower 12 extending from a support surface 14, a nacelle 16 mounted on the tower 12, and a rotor 18 coupled to the nacelle 16. The rotor 18 includes a rotatable hub 20 and at least one rotor blade 22 coupled to and extending outward from the hub 20. For example, in Figure 1 In the embodiment shown, rotor 18 includes three rotor blades 22. However, in alternative embodiments, rotor 18 may include more or fewer than three rotor blades 22. Each rotor blade 22 may be spaced around hub 20 to facilitate rotation of rotor 18 to convert kinetic energy from wind into usable mechanical energy and subsequently into electrical energy. For example, hub 20 may be rotatably coupled to generator 24 located within nacelle 16.

[0026] Figure 2 This is a perspective view of one of the rotor blades 22. As shown, the rotor blade 22 includes a component coupled to a rotatable hub 20. Figure 1The rotor blade 22 includes a blade root 26 and a blade tip 28 disposed opposite to the blade root 26. The rotor blade 22 may also include a pressure side 30 and an intake side 32 extending between the leading edge 34 and the trailing edge 36. Additionally, the rotor blade 22 may include a span 38 defining the total length between the blade root 26 and the blade tip 28, and a chord 40 defining the total length between the leading edge 34 and the trailing edge 36. Generally, as the rotor blade 22 extends from the blade root 26 to the blade tip 28, the chord 40 may vary in length along the span 38.

[0027] Now refer to Figure 3 The rotor blade 22 is formed of a shell 42. In some embodiments, the shell 42 includes a first shell portion 44 and a second shell portion 46 joined (e.g., adhesively joined) at or near the leading edge 34 and trailing edge 36 of the rotor blade 22. In this respect, the first shell portion 44 and the second shell portion 46 may extend along the entire span 38 and / or the entire chord 40. However, in alternative embodiments, the shell 42 may include more or fewer shell portions, and / or the shell portions may be joined at different locations on the rotor blade 22. Furthermore, in some embodiments, each shell portion may extend only a portion of the span 38 and / or chord 40.

[0028] like Figure 3 As shown, housing 42 includes outer surfaces defining various sides and edges of rotor blade 22. More specifically, first housing portion 44 includes an outer surface 48 defining the pressure side 30 of rotor blade 22. Second housing portion 46 includes an outer surface 50 defining the suction side 32 of rotor blade 22. Figure 3 In the embodiment shown, the first shell portion 44 and the second shell portion 46 are joined together such that the second shell portion 46 defines a leading edge 34 and / or the first shell portion 44 defines a trailing edge 36. However, in an alternative embodiment, the first shell portion 44 may define a leading edge 34, and the second shell portion 46 may define a trailing edge 36. In another embodiment, both the first shell portion 44 and the second shell portion 46 may define both a leading edge 34 and a trailing edge 36.

[0029] The shell 42 defines the inner cavity 52 therein. That is, the rotor blades 22 are generally hollow. Figure 3 In the embodiment shown, a first shell portion 44 defines an inner surface 54, and a second shell portion 46 defines an inner surface 56. In this respect, the inner surfaces 54, 56 of the first shell portion 44 and the second shell portion 46 define an inner cavity 52. ​​Various structural members positioned within the inner cavity 52 (which will be discussed in more detail below) divide the inner cavity 52 into various compartments.

[0030] exist Figure 3In the embodiment shown, the rotor blade 22 includes spar caps 58 and 60 positioned within an inner cavity 52. ​​Specifically, a first spar cap 58 (e.g., adhesively attached) is coupled to the inner surface 54 of the first shell portion 44. A second spar cap 60 (e.g., adhesively attached) is coupled to the inner surface 56 of the second shell portion 46. In this respect, the first spar cap 58 and the second spar cap 60 are generally resistant to bending stresses and / or other loads acting on the rotor blade 22 in the spanwise direction (i.e., parallel to the span 38 of the rotor blade 22) during operation of the wind turbine 10. Furthermore, the first spar cap 58 and the second spar cap 60 are resistant to spanwise compression of the rotor blade 22 that occurs during operation of the wind turbine 10. The first spar cap 58 and the second spar cap 60 may extend along the span 38 from the blade root 26 to the blade tip 28 or a portion thereof. Some embodiments of the rotor blade 22 may include zero, one, three, four, or more spar caps.

[0031] The rotor blade 22 also includes one or more shear webs 62 extending through the cavity 52 in a spanwise direction. In some embodiments, the shear webs 62 may be formed using the system 100 and / or method 200 described below. Each shear web 62 includes a first side 64 coupled to a first shell portion 44 and a second side 66 coupled to a second shell portion 46. In this respect, the shear webs 62 resist shear forces applied to the first shell portion 44 and the second shell portion 46. Figure 3 In the embodiment shown, the rotor blade 22 includes a shear web 62 guided to connect (e.g., bond) to the first spar cap 58 and the second spar cap 60. However, in alternative embodiments, the rotor blade 22 may include more shear webs 62, and / or the shear webs 62 may be directly connected (e.g., bonded) to the inner surfaces 54, 56 of the first shell portion 44 and the second shell portion 46. In further embodiments, the shear web 62 may extend in a direction along the chord (i.e., parallel to the chord 38 of the rotor blade 22).

[0032] Figure 4 An embodiment of a shear web 62 is shown. As shown, the shear web 62 may include a lattice structure 68 positioned between a first panel 70 and a second panel 72. In one embodiment, the lattice structure 68 and the panels 70, 72 may be formed as an integral structure. However, in an alternative embodiment, the lattice structure 68 and the panels 70, 72 may be separate components, adhesively joined together to form the shear web 62. The shear web 62 may have any suitable construction.

[0033] Figure 5The lattice structure 68 is shown in more detail. More specifically, the lattice structure 68 may define a plurality of open units 74, which provide a lightweight construction for the shear web 62. The units 74 may have any suitable shape and / or construction. Furthermore, the lattice structure 68 may be integrally formed as a single component or formed as a plurality of lattice structure portions connected together. Although the lattice structure 68 is shown as part of the shear web 62, the lattice structure 68 may be integrated into any component of the wind turbine 10, such as the first shell portion 44 and the second shell portion 46.

[0034] Figure 6 An embodiment of a system 100 for forming a fiber-reinforced polymer component 102 is shown. Generally, the fiber-reinforced polymer component 102 comprises one or more fiber bundles 103 surrounding or embedded within a polymeric solid 108. In some embodiments, for example, the fiber-reinforced polymer component 102 may be a component of a wind turbine 10, such as one or more of a shear web 62. However, in alternative embodiments, the fiber-reinforced polymer component 102 may be one or a portion of a sparsity cap 58, 60, a first shell portion 48, a second shell portion 46, a blade root 26, and / or any other suitable component of the wind turbine 10. In further embodiments, the fiber-reinforced polymer component 102 may be any suitable fiber-reinforced polymer component for any suitable application, including applications outside the wind turbine.

[0035] As shown, system 100 includes a reservoir 104 containing a polymerizable liquid 106. As will be described in more detail below, a portion of the polymerizable liquid 106 is irradiated to form a polymeric solid 108, which at least partially defines a fiber-reinforced polymer member 102. In several embodiments, reservoir 104 may include a bottom wall 110 and side walls 112, which together define a chamber 114 for containing the polymerizable liquid 106. The top of reservoir 104 may be open to allow continuous removal of the polymeric solid 108 from reservoir 104 during the formation of the fiber-reinforced polymer member 102. Furthermore, reservoir 104 may include an oxygen-permeable portion 116 positioned within the bottom wall 108. The oxygen-permeable portion 116 supplies oxygen to a portion of the polymerizable liquid 106 within reservoir 104. In this way, the oxygen-permeable portion 116 may be formed of a silicide or another suitable oxygen-permeable material. However, in other embodiments, reservoir 104 may have any suitable construction.

[0036] In some embodiments, the polymerizable liquid 106 may be any suitable liquefied thermoplastic material. As used herein, the term "thermoplastic material" generally includes any plastic material or polymer that is reversible in nature. For example, thermoplastic materials typically become flexible or moldable when heated to a certain temperature and return to a more rigid state upon cooling. Furthermore, thermoplastic materials may include amorphous thermoplastic materials and / or semi-crystalline thermoplastic materials. For example, some amorphous thermoplastic materials may generally include styrene, vinyl, cellulose, polyester, acrylic, polysulfone, and / or imide. More specifically, exemplary amorphous thermoplastic materials may include polystyrene, acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA), glycolised polyethylene terephthalate (PET-G), polycarbonate, polyvinyl acetate, amorphous polyamide, polyvinyl chloride (PVC), polyvinylidene chloride, polyurethane, or any other suitable amorphous thermoplastic material. Additionally, exemplary semi-crystalline thermoplastic materials may generally include polyolefins, polyamides, fluoropolymers, ethyl acrylates, polyesters, polycarbonates, and / or acetals. More specifically, exemplary semi-crystalline thermoplastic materials may include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polypropylene, polyphenylene sulfide, polyethylene, polyamide (nylon), polyetherketone, or any other suitable semi-crystalline thermoplastic material. In alternative embodiments, the polymerizable liquid 106 may be any UV-curable or light-curable resin, including suitable thermosetting materials.

[0037] System 100 also includes a build plate 118 having a build surface 120 on which fiber-reinforced polymer components 102 are formed. As shown, during the formation of the fiber-reinforced polymer components 102, polymeric solids 108 are coupled to the build plate 118 and extend from the build surface 120 into the polymerizable liquid 106 contained in the reservoir 104. The build plate 118 may be movable relative to the reservoir 104 to facilitate the removal of polymeric solids 108 from the reservoir 104. In particular, a suitable actuator (not shown) may cause the build plate 118 to move toward and away from the bottom wall 108 of the reservoir 104 (e.g., by means of...). Figure 6 (As indicated by arrow 122 in the diagram). In some embodiments, the actuator can cause the build plate 118 to move relative to the reservoir 104 at a constant or substantially constant speed.

[0038] System 100 also includes a radiation source 124, which is configured to emit radiation (e.g., as by...). Figure 6(As indicated by arrow 126) to irradiate a portion of the polymerizable liquid 106 contained in reservoir 104 to form a polymeric solid 108. More specifically, radiation source 124 may emit radiation 126 adapted to polymerize or otherwise solidify the polymerizable liquid 106 within reservoir 104 to form a polymeric solid 108. For example, in some embodiments, radiation 126 may be ultraviolet radiation. In such embodiments, radiation source 124 may be black light, short-wave ultraviolet lamp, gas discharge lamp, ultraviolet LED, ultraviolet laser, or any other suitable source for emitting ultraviolet radiation. However, in alternative embodiments, radiation 126 may be any suitable type of radiation, and / or radiation source 124 may be any suitable type of radiation source.

[0039] Furthermore, system 100 may include a mirror 128 configured to guide radiation 126 emitted by radiation source 124 into the build region 130 of reservoir 104. Generally, build region 130 is a portion of reservoir 104 irradiated with radiation 126. More specifically, when irradiated with radiation 126, polymerizable liquid 106 within build region 130 forms a portion of polymeric solid 108 having the same shape and size as build region 130. In this respect, build region 130 of reservoir 104 has a shape and size corresponding to the cross-section of a portion of the currently formed fiber-reinforced polymer member 102. In this way, build region 130 may define a single closed shape, such as... Figure 8 The generally circular outline shown, or defining several individual shapes, such as a lattice structure 68 ( Figure 4 The mirror 128 can adjust the shape, size, and / or position of the build region 130 in response to changes in the cross-section of a portion of the currently formed fiber-reinforced polymer member 102. Thus, in some embodiments, the mirror 128 may be a digital micromirror device (DMD) chip. However, in other embodiments, the mirror 128 may be any suitable means for directing radiation 124 into the reservoir 104. Furthermore, as shown, the mirror 128 may direct radiation 126 through the bottom wall 110 of the reservoir 104, such as through the oxygen-permeable portion 116. However, the mirror 128 may direct radiation 126 through any suitable wall or portion of the reservoir 104.

[0040] Still refer to Figure 6System 100 may include one or more fiber bundles 103 for supplying a reservoir 104 to a suitable component for impregnation with a polymerizable liquid 106. After impregnation, the fiber bundles 103 are positioned within a build region 130 for surrounding or embedding into a polymeric solid 108 (as described below) during irradiation. As shown, system 100 may include one or more mandrels 132 from which the fiber bundles 103 are released. The fiber bundles 103 are then passed through a tensioner assembly 134 having one or more tensioner wheels 136 that apply tension to each fiber bundle 103 to prevent any slack therein. An idler wheel 138 guides each fiber bundle 103 into the reservoir 104. In this way, the fiber bundles 132 are immersed in the polymerizable liquid 106 to form impregnated fiber bundles 140. The static guide device 142 guides each impregnated fiber bundle 140 toward the build area 130 for embedding or surrounding within the polymer solid 108. As shown, one end of each fiber bundle 103 can be coupled to the build plate 118. In this respect, as the build plate 118 and the polymer solid 108 move away from the bottom wall 110 of the reservoir 104, the build plate 118 and / or the polymer solid 108 release the fiber bundle 103 from the mandrel 134, thereby pulling the fiber bundle 103 through the respective wheels 136, 138, 142 and into the reservoir 104 for impregnation. Although Figure 6 Four fiber bundles 103 are shown, and more or fewer fiber bundles 103 can be impregnated for final enveloping or embedding within the polymeric solid 108 to form a fiber-reinforced polymer component 102. Furthermore, any suitable component or combination of components can supply fiber bundles 103 to the reservoir 104 for impregnation. Moreover, the component supplying fiber bundles 103 to the reservoir 104 for impregnation can be a static device (e.g., pulling a sleeve through the fiber bundle 103 to change its orientation) or a dynamic device (e.g., a wheel). For example, in one embodiment, a static device can guide the fiber bundles 103 when they are immersed in the polymerizable liquid 106, while a dynamic device can guide the fiber bundles 103 when they are not immersed in the polymerizable liquid 106.

[0041] Generally, fiber bundle 103 may comprise a plurality of individual continuous fibers. For example, in some embodiments, fiber bundle 103 may comprise a plurality of continuous carbon fibers or continuous glass fibers. However, fiber bundle 103 may comprise a plurality of polymer fibers, wood fibers, bamboo fibers, ceramic fibers, nanofibers, metal fibers, or other similar fibers or suitable combinations thereof.

[0042] Now refer to Figure 4-6System 100 may include one or more guide tools 144 configured to position impregnated fiber bundles 140 within a build region 130 of reservoir 104. As mentioned above, the shape, size, and / or position of build region 130 relative to build plate 118 may change in response to changes in the cross-section of fiber-reinforced polymer member 102. In this respect, guide tools 144 may adjust the position of impregnated fiber bundles 140 relative to build plate 130 such that the impregnated fiber bundles 140 remain within build region 130 of reservoir 104 when the cross-section of fiber-reinforced polymer member 102 changes. In the illustrated embodiment, system 100 includes four guide tools 144. Thus, system 100 may include one guide tool 144 for each impregnated fiber bundle 140. However, in alternative embodiments, system 100 may include any suitable number of guide tools 144. For example, system 100 may include multiple guide tools 144 positioned close together to position fiber bundles 103 close together.

[0043] like Figure 7 As best shown, the guide tool 144 can be positioned within the reservoir 104 between the build region 130 and the bottom wall 110. For example, the guide tool 144 can be positioned within a dead zone 146 of the reservoir 104, located between the build region 130 and the bottom wall 110. As mentioned above, the oxygen-permeable portion 116 of the reservoir 104 supplies oxygen (e.g., as from...) to a portion of the polymerizable liquid 116. Figure 7 (As indicated by arrow 148 in the diagram). Generally, the portion of the polymerizable liquid 116 containing oxygen 148 is referred to as the dead zone 146 and is located between the bottom wall 110 of the reservoir 104 and the construction region 130. For illustrative purposes, Figure 7 The dashed line 150 delineates the boundary between the dead zone 146 and the build region 130. Oxygen 148 in the dead zone 146 prevents the polymerizable liquid 106 from polymerizing or otherwise solidifying when radiation 126 passes through it. In this way, the guide tool 144 is positioned within the dead zone 146 to prevent the polymerizable liquid 106 in the dead zone 146 from solidifying on the guide tool 144. Furthermore, the dead zone 146 prevents the polymerizable liquid 106 therein from solidifying on the bottom wall 110 of the reservoir 104 and prevents the polymerized solid 108 from moving relative to the bottom wall 110. Oxygen 148 does not penetrate into the build region 130 and prevents polymerization therein.

[0044] As mentioned above, the guide tool 144 can adjust the position of the impregnated fiber bundle 140 relative to the construction plate 118. In some embodiments, such as Figure 8 As shown, the guide tool 144 can orient the impregnated fiber bundle 140 toward the center of the building plate 118 (e.g., as shown by...). Figure 7(as indicated by arrow 152 in the diagram) and away from the center of the building plate 118 (e.g., as ... Figure 7 (Indicated by arrow 154). In such embodiments, when the cross-section of the fiber-reinforced polymer member 102 is narrowed, the guide tool 144 can move the impregnated fiber bundles 140 in direction 152. Conversely, when the cross-section of the fiber-reinforced polymer member 102 is widened, the guide tool 144 can move the impregnated fiber bundles 140 in direction 154. Generally, the individual impregnated fiber bundles 140 are positioned at different locations within the build region 130. In some embodiments, the guide tool 144 is positioned around the entire periphery of the fiber-reinforced polymer member 102, such as around the member 102 at approximately 360 degrees. However, in alternative embodiments, the guide tool 144 can move the impregnated fiber bundles 140 in any suitable direction such that the impregnated fiber bundles 140 remain within the build region 130 during the formation of the fiber-reinforced polymer member 102.

[0045] Figure 9 An exemplary embodiment of one of the guide tools 144 is shown. As shown, the guide tool 144 includes an actuator 156 (e.g., a solenoid, electric motor, etc.) coupled to one end of a handle 158 and a ring 160 coupled to the other end of the handle 158. The ring 158 defines an aperture 162 through which a corresponding impregnated fiber bundle 140 is drawn. In this way, the ring 158 constrains the impregnated fiber bundle 140 in a plane parallel to the bottom wall 110 of the reservoir 104. In this respect, the guide tool 144 moves the corresponding impregnated fiber bundle 140 relative to the building plate 118 when the actuator 156 extends (i.e., moves the handle 158 in direction 152) or retracts (i.e., moves the handle 158 in direction 154). Although the aperture 162 of the guide tool 144 is shown to receive only one fiber bundle 103, the aperture 162 can receive any number of fiber bundles 103, such as two or more fiber bundles 103. In embodiments where the aperture 162 receives multiple fiber bundles 103, the guide tool 144 does not need to be positioned close together as in guide tools where the aperture 162 receives only one fiber bundle 103. However, in alternative embodiments, the guide tool 144 may have any suitable construction.

[0046] Refer again Figure 7 The system 100 may also include a controller 164 configured to electronically control the operation of one or more components of the system 100. Generally, the controller 164 may correspond to any suitable processor-based device, including one or more computing devices. Figure 7As illustrated, for example, controller 164 may include one or more processors 166 and one or more associated memory devices 168 configured to perform a variety of computer-implemented functions (e.g., performing the methods, steps, calculations, etc. disclosed herein). As used herein, the term "processor" refers not only to integrated circuits considered to be included in a computer in the art, but also to controllers, microcontrollers, microcomputers, programmable logic controllers (PLCs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), and other programmable circuits. Additionally, memory device 168 may generally include memory elements, including but not limited to: computer-readable media (e.g., random access memory (RAM)), computer-readable non-volatile media (e.g., flash memory), optical disc-read-only memory (CD-ROM), magneto-optical disc (MOD), digital versatile disc (DVD), and / or other suitable memory elements or combinations thereof. Memory device 168 may store instructions that, when executed by processor 166, cause processor 166 to perform various functions, such as those described below. Figure 10 The method 200 described includes one or more aspects. Additionally, the controller 164 may include various other suitable components, such as communication circuitry or modules, one or more input / output channels, data / control buses, etc.

[0047] In several embodiments, the controller 164 may be configured to control the guide tool 144 to position a portion of the impregnated fiber bundle 140 within the build region 130 of the reservoir 104. More specifically, the controller 164 may be communicatively coupled to the guide tool 144 via a wired or wireless connection to allow control signals to be transmitted (e.g., by...). Figure 7 (Indicated by the dashed line 170) to the guide tool 144. For example, control signal 170 may instruct actuator 156 of guide tool 144 to move corresponding handle 158 in direction 152 or direction 154 to position impregnated fiber bundle 140 within build region 130. In some embodiments, controller 164 may be configured to determine the position of build region 130 based on the desired geometry of fiber-reinforced polymer member 102.

[0048] The controller 164 can also be configured to control the radiation source 124 and / or the mirror 128 to irradiate the built-in region 130 of the reservoir 104. More specifically, the controller 164 can be communicatively coupled to the radiation source 124 via a wired or wireless connection to allow control signals to be transmitted (e.g., by...). Figure 7 (As indicated by the dashed line 172 in the image) to the radiation source 124. For example, control signal 172 may instruct radiation source 124 to emit radiation 126. Furthermore, controller 164 may be communicatively coupled to mirror 128 via a wired or wireless connection to allow control signals to be transmitted (e.g., by...). Figure 7(Indicated by the dashed line 174) to mirror 128. For example, control signal 174 may instruct mirror 128 to direct radiation 126 into reservoir 104 to irradiate build region 130. As mentioned above, controller 164 may be configured to determine the location of build region 130 within reservoir 104 based on the desired geometry of fiber-reinforced polymer component 102.

[0049] The controller 164 can also be configured to control an actuator (not shown) associated with the build plate 118 to move the build plate 118 continuously away from the build region 130 and the reservoir 104 when the build region 130 is irradiated. In this respect, moving the polymer solid 108 outside the build region 130 allows radiation 126 to irradiate the polymerizable liquid 106 flowing into the build region 130 in place of the polymer solid 108, thereby forming subsequent layers of the fiber-reinforced polymer component 102.

[0050] Additionally, controller 164 can be configured to adjust the size, shape, and / or position of the build region 130 within reservoir 104 relative to build plate 118. As indicated above, the cross-section of fiber-reinforced polymer component 102 can vary. In this respect, controller 164 can be configured to control mirror 128 and / or guide tool 144 (e.g., via control signals 170, 174, respectively) such that the positions of the irradiated build region 130 and the impregnated fiber bundle 140 correspond to the cross-section of a portion of the currently formed fiber-reinforced polymer component 102.

[0051] Figure 10 An embodiment of a method 200 for forming a fiber-reinforced polymer component according to aspects of this subject matter is shown. Although Figure 10 The steps described herein are for illustrative and explanatory purposes only and are performed in a particular order; however, the methods discussed herein are not limited to any particular order or arrangement. Thus, the individual steps of the methods disclosed herein may be omitted, rearranged, combined, and / or adjusted in various ways without departing from the scope of this disclosure.

[0052] like Figure 10 As shown, at (202), method 200 may include impregnating one or more fiber bundles with a polymerizable liquid contained in a reservoir to form one or more impregnated fiber bundles. For example, fiber bundle 103 may be drawn through polymerizable liquid 106 within reservoir 104 before entering build region 130 of reservoir 104 to form impregnated fiber bundle 140. As mentioned above, individual wheels (e.g., idler wheels 138, 142) may guide fiber bundle 103 into and through polymerizable liquid 106.

[0053] At (204), the method may include positioning one or more impregnated fiber bundles within the build area of ​​the reservoir. For example, as indicated above, controller 164 may be communicatively coupled to guide tool 144, thereby allowing controller 164 to transmit control signal 170 to guide tool 144, instructing guide tool 144 to position impregnated fiber bundle 140 within build area 130.

[0054] Furthermore, at (206), method 200 includes irradiating the build region of the reservoir to form a polymeric solid from a polymerizable liquid within the build region. For example, controller 164 may be communicatively coupled to radiation source 124, thereby allowing controller 164 to transmit control signal 172 to radiation source 124, instructing radiation source 124 to emit radiation 126, such as ultraviolet radiation. Additionally, controller 164 may be communicatively coupled to mirror 128, thereby allowing controller 164 to transmit control signal 174 to mirror 128, instructing mirror 128 to direct radiation 126 emitted by radiation source 124 into the build region 130 of the reservoir. As described above, radiation 126 polymerizes or otherwise solidifies the polymerizable liquid 106 within the build region 130 to form a polymeric solid 108, which surrounds fiber bundles 103 to at least partially define fiber-reinforced polymer components 102.

[0055] Additionally, at (208), method 200 may include continuously moving a build plate away from the build region while irradiating the build region. For example, while irradiating build region 130, an actuator (not shown) may continuously move build plate 118 away from build region 130 and reservoir 104, such as at a constant speed relative to reservoir 104. As indicated above, such continuous movement allows for the formation of each subsequent layer of fiber-reinforced polymer member 102.

[0056] Unlike conventional systems and methods, the system 100 and method 200 disclosed herein form fiber-reinforced polymer components in a continuous additive manner.

[0057] This written description uses examples to disclose the technology (including the best mode) and also enables any person skilled in the art to implement the technology, including making and using any device or system and performing any combined methods. The patentable scope of the technology is defined by the claims and may include other examples that would occur to a person skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements with non-material differences from the literal language of the claims.

Claims

1. A method for forming a fiber-reinforced polymer component, the method comprising: Impregnate the first fiber bundle with a polymerizable liquid contained in the reservoir to form the first impregnated fiber bundle; The first impregnated fiber bundle is positioned within the construction region of the reservoir, the construction region having a shape and size corresponding to the cross-section of the fiber-reinforced polymer component; as well as The build region of the reservoir is irradiated to form a polymeric solid from the polymerizable liquid within the build region, the polymeric solid surrounding a portion of the first fiber bundle to form at least a portion of the fiber-reinforced polymer component. The polymeric solid is attached to the building plate, and one end of the first fiber bundle is attached to the building plate, wherein as the building plate and the polymeric solid move away from the bottom wall of the reservoir, the building plate and / or the polymeric solid pull the first fiber bundle into the reservoir for impregnation.

2. The method according to claim 1, characterized in that, The method further includes: When the cross-section of the fiber-reinforced polymer component changes, at least one of the shape, size, or position of the building region is adjusted.

3. The method according to claim 2, characterized in that, The method further includes: When the cross-section of the fiber-reinforced polymer component changes, the position of the first fiber bundle is adjusted.

4. The method according to claim 3, characterized in that, Adjusting the position of the first fiber bundle includes using a guide tool positioned within a dead zone of the reservoir, the dead zone being located between the bottom wall of the reservoir and the construction area, the dead zone containing oxygen to prevent the polymerizable liquid from polymerizing.

5. The method according to claim 1, characterized in that, The method further includes: The polymerizable liquid contained in the reservoir is used to impregnate the second fiber bundle to form a second impregnated fiber bundle; and The second impregnated fiber bundle is positioned within the construction area of ​​the reservoir, in a portion of the construction area that is different from the first fiber bundle.

6. The method according to claim 1, characterized in that, The method further includes: Oxygen is supplied to the reservoir through an oxygen-permeable portion to create a dead zone within the reservoir, the dead zone being located between the bottom wall of the reservoir and the construction area, the oxygen preventing the polymerizable liquid from polymerizing.

7. The method according to claim 1, characterized in that, Irradiating the constructed area includes using a mirror to guide radiation into the constructed area of ​​the reservoir.

8. The method according to claim 1, characterized in that, The polymer solid is attached to the building plate.

9. The method according to claim 1, characterized in that, The method further includes: The construction plate is continuously moved away from the construction area while the construction area is being irradiated.

10. The method according to claim 1, characterized in that, Irradiating the constructed region includes irradiating the constructed region with ultraviolet radiation.

11. The method according to claim 1, characterized in that, The fiber-reinforced polymer component is a continuous fiber-reinforced polymer component.

12. The method according to claim 1, characterized in that, The first fiber bundle comprises multiple carbon or glass fibers.

13. The method according to claim 1, characterized in that, The fiber-reinforced polymer component is a wind turbine component.

14. The method according to claim 13, characterized in that, The wind turbine component is a shear-resistant web.

15. A method for forming a lattice-like portion of a continuous fiber-reinforced polymer wind turbine component, the method comprising: The first and second fiber bundles are impregnated with a polymerizable liquid contained in a reservoir to form the first impregnated fiber bundle and the second impregnated fiber bundle. The first impregnated fiber bundle and the second impregnated fiber bundle are positioned within the building region of the reservoir, the first fiber bundle being positioned at a different location within the building region than the second fiber bundle, the building region having a shape and size corresponding to the cross-section of the lattice portion of the fiber-reinforced polymer wind turbine component; The build area of ​​the reservoir is irradiated to form a polymeric solid from the polymerizable liquid within the build area. The polymeric solid is attached to a build plate and surrounds a portion of the first fiber bundle and a portion of the second fiber bundle to form at least a portion of the lattice portion of the fiber-reinforced polymer wind turbine component. The construction plate is continuously moved away from the construction area while the construction area is irradiated; as well as When the cross-section of the lattice portion of the fiber-reinforced polymer wind turbine is forced to change, at least one of the shape or size of the constructed region is adjusted. One end of the first fiber bundle and one end of the second fiber bundle are respectively connected to the building plate, wherein when the building plate and the polymer solid move away from the bottom wall of the reservoir, the building plate and / or the polymer solid pull the first fiber bundle and the second fiber bundle into the reservoir for impregnation.

16. The method according to claim 15, characterized in that, The method further includes: When the cross-section of the continuous fiber reinforced polymer wind turbine component changes, the positions of the first fiber bundle and the second fiber bundle are adjusted.

17. The method according to claim 16, characterized in that, Adjusting the positions of the first fiber bundle and the second fiber bundle includes adjusting the position of the first fiber bundle using a first guiding tool and adjusting the position of the second fiber bundle using a second guiding tool. The first guiding tool and the second guiding tool are positioned within a dead zone of the reservoir, the dead zone being located between the bottom wall of the reservoir and the construction area, the dead zone containing oxygen to prevent the polymerizable liquid from polymerizing.

18. The method according to claim 15, characterized in that, The continuous fiber reinforced polymer wind turbine component is a shear-resistant web.

19. A system for forming fiber-reinforced polymer components, the system comprising: A reservoir containing a polymerizable liquid, the reservoir including a building region having a shape and size corresponding to the cross-section of the fiber-reinforced polymer member, the reservoir also including a dead zone positioned between the bottom wall of the reservoir and the building region, the dead zone containing oxygen for preventing the polymerizable liquid from polymerizing; A mirror configured to direct radiation into a construction region of the reservoir, the radiation being formed into a polymeric solid by the polymerizable liquid within the construction region; A guiding tool, positioned within the dead zone of the reservoir, the guiding tool being configured to position an impregnated fiber bundle within the construction area of ​​the reservoir; as well as A controller communicatively coupled to the mirror and the guiding tool, the controller being configured to control the guiding tool to position the impregnated fiber bundle within the build area of ​​the reservoir, and the controller also being configured to control the mirror to irradiate the build area of ​​the reservoir. The polymeric solid is connected to the building plate, and one end of the impregnated fiber bundle is connected to the building plate, wherein when the building plate and the polymeric solid move away from the bottom wall of the reservoir, the building plate and / or the polymeric solid pull the impregnated fiber bundle into the reservoir for impregnation.

20. The system according to claim 19, characterized in that, The controller is configured to control the guide tool to adjust the position of the fiber bundle when the cross-section of the fiber-reinforced polymer component changes.

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