Flexible Airtight Container for Wind Turbine Blade Fibre Layup
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Solution Overview
Problem
The manufacturing of wind turbine blades using fibre-reinforced composite materials is time-consuming, particularly when using dry fibres that require polymer infusion, as the layup process is cumbersome and prone to delays due to the need for polymer infusion after the layup is completed.
Innovation Solution
A container with a cavity that maintains a reduced pressure and is impermeable to polymer, allowing fibre material to be laid up and shaped remotely from the mould, preventing polymer ingress until infusion, and featuring a flexible airtight material to support and maintain the fibre material's shape during transport and layup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dry fibre material is laid up and polymer infusion is performed after layup completion, then the layup process can be performed on a mould to achieve desired shape, but the manufacturing process becomes time-consuming and increases turnaround time
Solution Approach 1:
The fibre material is pre-impregnated with polymer in a first container before being transferred to the mould, eliminating the need for post-layup infusion. This preliminary impregnation action allows the fibre to arrive at the mould already prepared, significantly reducing manufacturing time while maintaining shape accuracy through the container's confinement
Solution Approach 2:
The manufacturing process is divided into separate stages: fibre impregnation in a first container, then transfer to the mould for final assembly. This segmentation allows impregnation to occur independently before the fibre reaches the mould, enabling parallel processing and reducing overall turnaround time
2Productivity
If fibre material is laid up remotely from the mould, then transport time is reduced and productivity improves, but the fibre material may be damaged or deformed during transport
Solution Approach 1:
A flexible container with a bottom surface conforming to the fibre material's shape is used to enclose and protect the fibre during transport. This flexible shell maintains the fibre's structural integrity while allowing the container to be easily formed and adapted to different fibre configurations
Solution Approach 2:
The container acts as an intermediary between the fibre material and the external environment during transport. It provides mechanical support and protection, preventing damage and deformation while allowing the fibre to be moved remotely from the mould without direct handling
3Reliability
If the container is made permeable to allow polymer flow, then polymer can reach the fibre material, but polymer may ingress into the cavity unintentionally before infusion
Solution Approach 1:
The container wall has different permeability properties at different locations: the bottom surface in contact with the fibre material is permeable to allow polymer flow, while the sides and top are impermeable to prevent unintentional ingress. This localized quality differentiation enables controlled polymer transfer while preventing contamination
Solution Approach 2:
Pressure differentials are used to control polymer flow through the container wall. By applying positive pressure inside the container or negative pressure outside, polymer is directed to flow only through the intended permeable bottom surface, preventing unintended ingress through other areas
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
Enables efficient layup of fibre materials with reduced turnaround time by allowing pre-arrangement of fibre materials outside the mould, maintaining the shape and preventing polymer ingress until infusion, thus minimizing disruptions during the infusion process.
Implementation Method 1
The cavity has a cavity pressure and comprises fibre material... a ratio of an entire volume of non-cured polymer in the cavity to an entire volume of the fibre material in the cavity is less than 0.3... the container is adapted to prevent inflow of a polymer into the cavity
Implementation Method 2
the cavity pressure is maintained below a threshold pressure of 800 hPa... the cavity is passively sealed off to maintain the pressure below the threshold pressure
Data Source
AI summary
The present invention relates to a container having a cavity, wherein the cavity has a cavity pressure and comprises fibre material suitable for manufacturing one or more fibre-reinforced composite components for a wind turbine blade, and at least a part of the fibre material touches a first part of a wall of the container, at least the first part of the wall consisting of a flexible airtight material, and a ratio of an entire volume of non-cured polymer in the cavity to an entire volume of the fibre material in the cavity is less than 0.3, and the container is adapted to prevent inflow of a polymer into the cavity. A method for preparing such a container is also disclosed. A method for laying fibre material into a mould is also disclosed.