Wind Turbine Blade Composite Laminate with Segmented Flow Strips
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Solution Overview
Problem
Existing methods for manufacturing composite laminate structures for wind turbine blades face challenges in promoting resin flow while maintaining conductivity through the thickness of the structure, particularly with carbon fibre layers, which is crucial for lightning protection.
Innovation Solution
The method involves alternately stacking fibre-reinforcement layers with electrically conductive fibres and flow strip layers in a resin transfer moulding process, where the flow strips create voids to facilitate resin flow without isolating the fibre layers, ensuring conductivity through the thickness of the laminate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a conventional flow media is placed to aid resin flow during infusion, then resin flow is improved, but conductivity between carbon fibre layers is significantly reduced
Solution Approach 1:
The flow media is segmented into discrete flow strips arranged in a pattern with voids between them, rather than using a continuous flow media. This segmentation allows resin to flow through the voids while maintaining contact between carbon fibre layers, thus preserving conductivity while still aiding resin distribution.
Solution Approach 2:
Different regions of the mould cavity have different properties: areas with flow strips provide resin flow pathways, while voids between strips maintain conductivity. This local differentiation allows simultaneous achievement of both resin infusion and electrical conductivity requirements in different locations.
2Reliability
If fibre layers are stacked closely together to maintain conductivity, then conductivity is improved, but resin flow through the layers is hindered
Solution Approach 1:
The flow media is divided into discrete strips with voids between them, creating localized flow pathways that do not require separating entire fibre layers. Resin can flow through the voids while fibre layers remain in contact for conductivity.
Solution Approach 2:
The flow pathways are introduced in the planar dimension (horizontal flow between strips) rather than requiring vertical separation of layers. This allows resin to flow through the thickness direction via voids without compromising the lateral contact between fibre layers needed for conductivity.
3Ease of manufacture
If a continuous flow media is used to ensure resin distribution, then resin infusion is improved, but the complexity of the structure increases
Solution Approach 1:
Instead of a continuous flow media that would require complex integration with fibre layers, the solution uses simple discrete strips arranged in a pattern. This segmented approach simplifies the overall structure while maintaining effective resin distribution through the voids between strips.
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
This approach effectively promotes resin infusion and maintains conductivity, enabling the production of composite structures with thick carbon fibre or hybrid layers that are properly wetted and protected against lightning strikes.
Implementation Method 1
a flow strip layer in form of a layer of flow strips, each having a strip width, and which are arranged so as to form voids or spacings having a void width
Implementation Method 2
manufacturing a composite laminate structure of a wind turbine blade part by means of resin transfer moulding, preferably vacuum-assisted resin transfer moulding
Data Source
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AI summary
The present disclosure relates to a method of manufacturing a composite laminate structure of a wind turbine blade part by means of resin transfer moulding, preferably vacuum-assisted resin transfer moulding. The fibre-reinforcement material is impregnated with liquid resin in a mould cavity, wherein the mould cavity comprises rigid mould part having a mould surface defining a surface of the wind turbine blade part. The method comprises alternately stacking on the rigid mould part: i) a number of fibre-reinforcement layers (42,46) comprising electrically conductive fibres, such as carbon fibres, and ii) a flow strip layer (62) in form of a layer of flow strips (62a, 62b, 62c) having a strip width and which are arranged so as to form voids having a void width between two juxtaposed strips. The method comprises sealing a second mould part against the rigid mould part in order to form the mould cavity. The method comprises optionally evacuating the mould cavity, such as in vacuum-based infusion. The method comprises supplying a resin to the mould cavity, i.e. the infusion phase. The method comprises curing or hardening the resin in order to form the composite laminate structure.