Wind Turbine Blade Safety Edge via Resin-Impermeable Foam
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Solution Overview
Problem
The existing manufacturing processes for wind turbine blades result in rough, hazardous edges due to uneven resin infusion and excess resin, making handling unsafe and requiring costly and time-consuming trimming processes.
Innovation Solution
A method involving arranging fibrous layers and resin-impermeable edging in a mould, integrating them with resin, and severing the edging to reveal a resin-free surface, creating a safe edge without extensive post-fabrication processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glass fibre layers are laid up in a mould to form a composite component, then the component structure is created, but the edge becomes rough and hazardous due to uneven resin infusion and excess resin
Solution Approach 1:
An edging component is introduced as an intermediary element between the glass fibre layers and the external environment. This edging is integrated with the laminate by resin infusion and provides a protective barrier that prevents direct contact with the rough, hazardous edges of the cured composite component.
Solution Approach 2:
The edging is arranged adjacent to the laminate edge before resin infusion occurs. This preliminary positioning allows the edging to be integrated with the laminate structure during the curing process, ensuring that the protective edge is formed as part of the manufacturing process rather than as a post-processing step.
2Object-affected harmful factors
If the rough edge is removed by trimming with a diamond cutting saw, then the hazardous edge is eliminated, but the process becomes expensive and time-consuming
Solution Approach 1:
The edging serves as a mediator that eliminates the need for time-consuming diamond cutting saw trimming. By providing a protective barrier during manufacturing, the hazardous edge is prevented from forming in the first place, eliminating the need for post-curing trimming operations.
Solution Approach 2:
The resin that would normally create hazardous serrations at the edge is instead used to bond the edging to the laminate. The potential harm of excess resin is converted into a beneficial bonding agent that secures the protective edging in place.
3Object-affected harmful factors
If the edge is neatened by folding over glass fibre layer edges, then some roughness is reduced, but trimming is still required post-fabrication
Solution Approach 1:
Instead of relying on folding glass fibre edges which only partially mitigates roughness, an edging component is introduced as a superior intermediary solution. This edging provides complete edge protection and eliminates the need for post-fabrication trimming, significantly improving productivity.
4Shape
If an abutment piece is provided in the mould tool, then the edge is neater upon de-moulding, but fractured resin regions still present sharp hazardous edges
Solution Approach 1:
The edging component serves as a more effective intermediary than a simple abutment piece. While the abutment only improves neatness, the edging provides continuous protective coverage that eliminates sharp hazardous edges from fractured resin regions.
Solution Approach 2:
The edging provides localized protection specifically at the vulnerable edge region where hazardous sharp edges would form. This targeted approach ensures that the specific problem of sharp edge hazards is addressed without affecting the overall component design.
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 method provides a simple and efficient way to create a hand-safe edge on composite components, eliminating the need for elaborate tools and lengthy processing, while ensuring the edge is safe and easy to handle without resin-related hazards.
Implementation Method 1
integrating the fibrous layers and the edging by means of resin
Implementation Method 2
substantially preventing the resin from permeating into the edging
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5D
AI summary
A composite component (130) such as a shear web for a wind turbine blade is described. The component comprises a moulded laminate (44) formed from one or more fibrous layers (40) integrated by resin and defining a laminate edge (48). An edging strip (60) is located adjacent to the laminate edge (48) and is integrated with the laminate. In a particular example, the edging (60) is made from closed-cell foam. Accordingly, resin does not permeate into the bulk of the edging (60) during the moulding process. After the moulding process, a portion (60a) of the edging (60) is removed to reveal an exposed, substantially resin-free surface of the edging which defines a safety edge (64) of the component.