Foam Core Rotor Blade Components with Elastomeric Cover Skin
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing rotor blade components for wind turbines are time-consuming and result in brittle, heavy parts that are not flexible enough to move with the rotor blades, leading to increased production costs and reduced efficiency.
Innovation Solution
A method involving a mold coated with elastomeric material, where a foam material is inserted and allowed to cure, forming a lightweight, flexible rotor blade component with a cover skin, and optionally additional support members for enhanced strength and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fiberglass composite material is used for rotor blade components, then structural strength is improved, but weight increases and flexibility decreases
Solution Approach 1:
The patent uses a composite structure combining foam core material with fiberglass composite layers. The foam core provides lightweight structural support while the fiberglass layers provide surface strength and weather resistance. This composite approach achieves the required structural strength while significantly reducing weight compared to solid fiberglass construction.
Solution Approach 2:
The patent employs foam core material with a porous cellular structure as the internal framework. This porous material provides high strength-to-weight ratio, structural integrity, and flexibility, allowing the component to move with the rotor blade while maintaining strength. The foam core replaces heavy solid fiberglass with lightweight porous material.
2Strength
If fiberglass composite material is used for rotor blade components, then structural strength is improved, but flexibility to move with blades deteriorates
Solution Approach 1:
The composite construction with foam core and fiberglass layers creates a structure that combines rigidity where needed with flexibility where required. The foam core provides elastic deformation capability allowing the component to flex with the rotor blade, while the fiberglass layers maintain surface integrity and strength.
Solution Approach 2:
The patent adjusts the thickness and density parameters of the foam core material to optimize the balance between strength and flexibility. By controlling foam density and layer thickness, the component achieves sufficient flexibility to move with the blades during operation while maintaining required structural strength.
3Manufacturing precision
If traditional RTM manufacturing process is used, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The mold is pre-coated with release agent before assembly, and the foam core material is pre-cut and shaped to fit the mold cavity. This preliminary preparation allows for faster assembly and reduces the overall manufacturing cycle time while maintaining precision through the use of precision-machined mold cavities and pre-formed components.
Solution Approach 2:
The patent replaces the traditional resin transfer molding process with a foam injection or assembly process. This substitution eliminates the time-consuming vacuum resin infusion and extended cure cycles, significantly reducing production time while maintaining manufacturing precision through controlled foam expansion and precise mold fitting.
4Reliability
If fiberglass composite material is used for rotor blade components, then durability is improved, but production cost increases
Solution Approach 1:
The foam core and fiberglass layer composite structure provides durable, weather-resistant components at lower cost than traditional solid fiberglass construction. The foam core reduces material costs while the fiberglass layers provide necessary durability and weather protection, achieving cost-effective manufacturing without sacrificing reliability.
Solution Approach 2:
The foam core material provides cost-effective structural support compared to expensive solid fiberglass or metal alternatives. The porous foam structure is easier and cheaper to manufacture while maintaining sufficient durability for wind turbine applications, reducing overall production costs while preserving component reliability.
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 method produces lightweight, flexible, and durable rotor blade components that can flex with the blades during operation, reducing production time and costs while maintaining structural integrity.
Implementation Method 1
the elastomeric material forms a cover skin around at least a portion of the rotor blade component
Implementation Method 2
inserting a foam material within the mold
Data Source
AI summary
Methods of manufacturing rotor blade components for a wind turbine and rotor blade components produced in accordance with such methods are disclosed. In one embodiment, the method generally includes providing a mold of the rotor blade component; coating at least a portion of an interior surface of the mold with an elastomeric material; inserting a foam material within the mold; and, removing the rotor blade component from the mold, wherein the elastomeric material forms a cover skin around at least a portion of the rotor blade component. In an alternative embodiment, the method includes providing at least one support member defining a profile for the rotor blade component on a mold surface; coating at least a portion of the support member with an elastomeric material; and, allowing the elastomeric material to cure on the mold surface so as to form the rotor blade component.