Conductive Mesh Composite Panels for Wind Turbine Lightning Protection
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Solution Overview
Problem
Conventional composite material panel structures for wind turbine nacelle covers are non-conductive, requiring separate anti-lightning structures like shield wires, which are costly and labor-intensive to install, and adding metal foils or plates increases weight without providing effective lightning current release.
Innovation Solution
Incorporating a conductive mesh sheet on the surface of composite material panels, allowing electrical connection between panels to form a lightning current path, eliminating the need for separate anti-lightning structures and reducing weight and cost by using the mesh sheet to diffuse resin during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shield wire is disposed inside the nacelle cover to provide anti-lightning function, then lightning protection is achieved, but the structure becomes complex and installation becomes laborious and costly
Solution Approach 1:
The patent combines the anti-lightning function with the composite material panel itself by incorporating conductive mesh sheets into the panel structure. Instead of adding a separate shield wire system, the conductive mesh is integrated during manufacturing, merging the structural and lightning protection functions into a single unified component.
Solution Approach 2:
The composite material panel with integrated conductive mesh provides its own lightning protection capability without requiring external shield wires or separate protection systems. The panel structure itself becomes self-sufficient for both structural and anti-lightning functions.
2Reliability
If metal foil or plate is laminated onto the prepreg to make the composite material conductive, then electrical conductivity is achieved, but the weight of the panel increases
Solution Approach 1:
The patent uses a thin conductive mesh sheet instead of bulky metal foils or plates. The mesh structure provides the necessary electrical conductivity while maintaining minimal thickness and weight, allowing the composite panel to remain lightweight while achieving the required conductive properties for lightning protection.
Solution Approach 2:
The patent creates a composite structure by integrating the conductive mesh sheet with the fiber-reinforced base material and matrix resin. This composite approach combines the mechanical strength of the base material with the electrical conductivity of the mesh, achieving both structural integrity and electrical functionality without excessive weight.
3Strength
If an autoclave molding method is used to manufacture composite material, then strong composite material is obtained, but the cost increases due to requirement of large-scale autoclave facility
Solution Approach 1:
The patent divides the manufacturing process into manageable stages that can be performed without a complete autoclave system. By using vacuum bagging for resin impregnation and curing, the process is segmented into steps that can be carried out in smaller, more cost-effective facilities while still achieving the required material strength.
Solution Approach 2:
The patent introduces a mold releasing film as an intermediary layer between the mold and the composite material during manufacturing. This allows for easy demolding and simplifies the manufacturing process, enabling production without requiring expensive autoclave facilities while maintaining product quality.
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 conductive mesh sheet enables the composite material panels to form a lightning current path, providing an anti-lightning function without additional structures, reducing equipment costs and weight, while ensuring secure bonding and efficient resin diffusion.
Implementation Method 1
the conductive mesh sheets of a plurality of the composite material panels are electrically connected to each other, thereby a lightning current path is formed in the composite material panel structure
Implementation Method 2
an inner side of the bag film 105 is subjected to vacuum suction, whereupon a liquid resin is injected into an interior of the bag film 105 and cured
Data Source
AI summary
The present invention provides a composite material panel structure and a manufacturing method thereof with which an anti-lightning function can be realized without adding a separate anti-lightning structure to the composite material panel structure. In a composite material panel structure formed from a composite material panel containing reinforcing fibers, the composite material panel includes: a fiber-reinforced base material impregnated with a matrix resin; a conductive mesh sheet disposed on one surface side of the fiber-reinforced base material; and a bag film disposed on the one surface side of the fiber-reinforced base material so as to sandwich the conductive mesh sheet. The conductive mesh sheets of a plurality of the composite material panels are electrically connected to each other.