Conductive Woven Fabric with Integrated Resin Flow Passages
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Solution Overview
Problem
Existing conductive fabrics for wind turbine rotor blades are heavy, costly, and have excessive electrical conductivity, failing to meet weight and conductivity requirements efficiently.
Innovation Solution
A woven fabric composed of unidirectional reinforcing fibers, electrical conductive fibers, and flow passages forming elements, arranged transversely to provide optimal conductivity and permeability, using vacuum-induced resin infusion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If low weight carbon biaxial fabrics are used for interlayer, then weight is reduced, but electrical conductivity becomes insufficient
Solution Approach 1:
The patent combines glass fibers (for weight reduction and cost) with carbon fibers (for electrical conductivity) in a hybrid woven fabric. The glass fibers provide structural support and reduce weight, while the carbon fibers form conductive pathways at specific orientations (0° and 90°) to ensure adequate electrical conductivity for lightning strike protection.
Solution Approach 2:
The patent applies different fiber types in different orientations within the same fabric. Carbon fibers are specifically positioned at 0° and 90° orientations to create electrical conductive pathways, while glass fibers fill other orientations to reduce weight and cost. This local differentiation of material properties optimizes both conductivity and weight.
2Reliability
If carbon fibers are used for electrical conductivity, then conductivity is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses carbon fibers only where needed for electrical conductivity (at 0° and 90° orientations), rather than throughout the entire fabric. Glass fibers are used in other orientations where structural support is needed but electrical conductivity is not critical, thereby reducing material costs while maintaining conductivity requirements.
Solution Approach 2:
The hybrid glass/carbon fiber combination leverages the cost-effectiveness of glass fibers for structural support while using carbon fibers specifically for conductivity functions, optimizing the cost-performance ratio compared to using carbon fibers exclusively.
3Reliability
If existing conductive fabrics are used, then electrical conductivity is achieved, but weight and cost are excessive
Solution Approach 1:
The patent creates a hybrid fabric combining glass and carbon fibers, where glass fibers provide structural support and weight reduction, while carbon fibers provide electrical conductivity. This composite approach achieves the required conductivity with lower weight than existing carbon-only conductive fabrics.
Solution Approach 2:
Carbon fibers are strategically positioned only at orientations where electrical conductivity is critical (0° and 90°), while glass fibers are used in other orientations. This localized use of carbon fibers reduces the overall carbon content and weight while maintaining sufficient conductivity.
4Productivity
If flow passages forming elements are added to improve resin flow, then permeability is improved, but fabric complexity increases
Solution Approach 1:
The patent uses the weft yarns to serve dual functions: providing structural support as reinforcing elements and simultaneously forming flow passages for resin infusion. The weft yarns are positioned and sized to create channels that facilitate resin flow, eliminating the need for separate flow promoter layers or complex three-dimensional structures.
Solution Approach 2:
The patent extracts the flow passage formation function from the reinforcing structure by designing the weft yarn arrangement to naturally create flow channels. This integration eliminates the need for additional flow promoter layers or complex three-dimensional flow control structures, simplifying the overall fabric 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
The fabric achieves reduced weight, sufficient electrical conductivity, and cost-effective manufacturing, with improved flow characteristics and interlaminar shear properties.
Implementation Method 1
vacuum induced resin infusion process
Implementation Method 2
Vacuum induced resin infusion process
Data Source
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AI summary
The present invention relates to a woven fabric for the manufacture of fibre reinforced composites having an area weight from 100 to 200 g/m2 which comprises unidirectional reinforcing fibres, carbon fibres and flow passages forming elements arranged in warp and/or weft direction, and, optionally additives. The flow passages forming elements are arranged transverse to the reinforcing fibres and the carbon fibres forming flow passages at the side of the flow passages forming elements. Moreover, the present invention relates to a vacuum induced resin infusion process for forming a fibre reinforced composite from such woven fabric as well as the fibre reinforced composite.