Binding Agent Threads in Non-Woven Fabric Preforms
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Solution Overview
Problem
Large wind turbine blades face manufacturing defects due to inaccuracies in layer placement during the manufacturing process, which are not easily detectable and can affect aerodynamic performance and strength, leading to increased costs and material waste.
Innovation Solution
A non-woven fabric with stitching rows containing a binding agent is used to maintain fibre layer arrangement, allowing controlled adherence and rigidity, reducing manufacturing time and defects by eliminating the need for extensive binding agent application between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If smaller preforms of fabrics are placed together to reduce cycle time and improve quality, then manufacturing defects are reduced and cycle time is decreased, but the complexity of assembling and consolidating multiple preforms increases
Solution Approach 1:
The blade manufacturing process is divided into multiple smaller preforms that are assembled together, rather than using a single large fabric piece. This segmentation allows for better quality control and reduced defects while managing complexity through standardized modular units
Solution Approach 2:
The binding agent is applied in advance during preform consolidation, creating pre-assembled units with built-in adhesion. This preliminary action eliminates the need for extensive binding agent application during final blade assembly, reducing both cycle time and operational complexity
2Stability of the object's composition
If binding agent is applied as powder and/or sprayed between each layer, then layer consolidation is achieved, but the layup time increases significantly
Solution Approach 1:
The binding agent is applied in advance during preform consolidation rather than during final blade assembly. This preliminary application of binding agent between layers creates pre-consolidated units, dramatically reducing the time required during the main manufacturing process
Solution Approach 2:
The binding agent serves dual purposes: it consolidates layers within preforms and also facilitates the assembly of multiple preforms into the final blade structure. This self-service approach eliminates the need for separate binding agent application steps
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method reduces manufacturing defects and time while maintaining the structural integrity and aerodynamic performance of wind turbine blades, making the process more cost-effective and efficient.
Implementation Method 1
at least one thread comprises a binding agent
Data Source
AI summary
The present invention relates to a non-woven fabric comprising one or more fibre layers each comprising a plurality of fibres arranged along a fibre direction, wherein the non-woven fabric comprises a plurality of stitching rows, each stitching row comprising one or more threads arranged along a stitch direction, for maintaining arrangement of the plurality of fibres in the one or more fibre layers relative to each other, wherein at least one thread comprises a binding agent. The present invention further relates to preforms comprising the non-woven fabric according to the present invention and methods for producing the non-woven fabric, preforms and wind turbine blades.