Composite Blade Segmentation via Overlapping Fibre Resin Impregnation
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Solution Overview
Problem
The manufacturing of large wind turbine blades poses challenges due to the need for extensive and costly infrastructure for mould assemblies, and existing methods of dividing blades into sections result in mechanical weaknesses at connection points.
Innovation Solution
A method involving the manufacture of separate composite structures with fibre layers extending from each end, which are then overlapped and impregnated with liquid resin to form a continuous composite structure, eliminating boundary surfaces that can cause structural weaknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If blades are divided into separate sections for manufacturing, then transportation and infrastructure costs are reduced, but mechanical weaknesses and reliability deteriorate at connection points
Solution Approach 1:
The blade is divided into multiple sections that are manufactured separately in smaller moulds, then assembled on-site. This segmentation enables transportation and manufacturing in facilities with limited infrastructure while maintaining the ability to create a complete functional blade through assembly of the sections
Solution Approach 2:
Separate blade sections are joined together using mechanical connection means (such as bolts and flanges) to form a complete blade assembly. The merging of sections creates a structurally integrated blade that achieves both the transportation benefits of segmentation and the structural integrity of a unified design
2Length of moving object
If mould assemblies are made larger to produce longer blades, then blade length increases, but infrastructure costs and ceiling height requirements increase
Solution Approach 1:
Instead of using a single large mould assembly to produce long blades, the blade is segmented into multiple shorter sections that can be manufactured in smaller, more economically viable moulds. These sections are then assembled to achieve the desired total blade length, thereby avoiding the need for expensive infrastructure with high ceiling heights
3Ease of operation
If mechanical connection means are used to join blade sections, then assembly is simplified, but local weaknesses and potential breakdowns occur
Solution Approach 1:
Blade sections are connected through mechanical means such as flanges and bolts that merge the sections into a unified structural assembly. This merging approach maintains structural integrity while allowing for practical assembly and disassembly operations
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 allows for the production of long composite structures with enhanced strength and reduced likelihood of mechanical weaknesses, enabling more efficient manufacturing and transportation of wind turbine blades while minimizing the need for extensive infrastructure.
Implementation Method 1
distribution layers or distribution tubes, also called inlet channels, are used between the vacuum bag and the fibre material in order to obtain as sound and efficient a distribution of polymer as possible
Implementation Method 2
By generating a vacuum, typically 80% to 95% of the total vacuum, in the mould cavity between the inner side of the mould part and the vacuum bag, the liquid polymer can be drawn in and fill the mould cavity with the fibre material contained herein
Implementation Method 3
The polymer can be thermoset plastic or thermoplastics
Data Source
AI summary
A method of producing a composite structure comprising fiber reinforced material and having a longitudinal direction is described. The method comprises the following steps: a) manufacturing a first structure comprising a first cured composite part having a first thickness and a longitudinal direction with a first end, and a number of first fiber layers extending from the first end, b) manufacturing a second structure comprising a second cured composite part having a second thickness and a longitudinal direction with a second end, and a number of second fiber layers extending from the second end, and c) arranging the first structure and the second structure so that the first end faces towards the second end, and arranging the first fiber layers and the second fiber layers so that at least a part of the first fiber layers overlap at least a part of the second fiber layers in the longitudinal direction, d) supplying liquid resin in order to impregnate the first fiber layers and the second fiber layers, and e) curing the liquid resin in order to form the composite structure comprising the first cured composite part, the second cured composite part, and an intermediate composite part including the first fiber layers and the second fiber layers.