Modular Channel Members for Wind Turbine Blade Preform Vacuum Consolidation

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Solution Overview

Problem

Existing methods for manufacturing preforms for wind turbine blades are costly and inefficient, particularly due to high wear of vacuum profiles and insufficient flexibility when molding preforms of various shapes and sizes.

Innovation Solution

A method involving a mould assembly with elongate channel members fastened to the mould surface, each channel member having slits oriented transversely to its longitudinal axis, allowing for precise vacuum consolidation of fibre materials and binding agents, even in complex geometries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If polymer vacuum profiles or perforated tubes are used for applying vacuum during preform manufacturing, then vacuum consolidation can be achieved, but high wear occurs and flexibility is insufficient when molding preforms of various shapes and sizes

Engineering Contradiction:

Improvevacuum consolidation capabilityVSAvoidflexibility for various preform shapes and sizes

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The vacuum profile is divided into multiple modular channel members that can be selectively arranged and combined. Each channel member contains vacuum channels with transverse slits, and the modular design allows adaptation to different preform geometries while maintaining reliable vacuum consolidation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The channel members are designed to be movable and reconfigurable within the mould assembly, allowing the vacuum system to adapt dynamically to different preform shapes and sizes. This dynamic arrangement provides both reliability for vacuum application and versatility for various geometries.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If multiple vacuum profiles are used to form preforms of various shapes and sizes, then different preform geometries can be achieved, but manufacturing costs increase due to high wear and insufficient flexibility

Engineering Contradiction:

Improvecapability to form various preform geometriesVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The modular channel members are designed as universal components that can be reused across different preform manufacturing operations. Each channel member with transverse slits can adapt to various preform geometries, eliminating the need for multiple specialized vacuum profiles and reducing manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The durable channel members with transverse slits are designed to withstand repeated use without significant wear. After each preform manufacturing cycle, the channel members are recovered and reused for the next preform, reducing the frequency of replacement and lowering overall manufacturing costs.

Inventive Principle:

Principle #34Discarding and recovering

3Reliability

If conventional vacuum profiles are used for preform manufacturing, then vacuum application is possible, but the mould assembly requires frequent replacement and has short lifetime

Engineering Contradiction:

Improvevacuum application functionVSAvoidmould assembly lifetime

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The channel members are designed as replaceable modular units rather than permanent fixed components. If wear occurs, individual channel members can be replaced without replacing the entire mould assembly, effectively extending the mould assembly's lifetime while maintaining reliable vacuum application.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The channel members are designed with robust construction and transverse slit configuration that anticipates wear from repeated vacuum application. This beforehand cushioning against wear extends the operational lifetime of the mould assembly while maintaining reliable vacuum function.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 approach reduces manufacturing costs and increases efficiency by providing a more flexible and durable mould assembly that can handle complex preform shapes, resulting in improved precision and reduced layup mistakes.

Implementation Method 1

applying negative pressure to the fibre material and the optional binding agent via the one or more channel members for consolidating the part

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentUS20250050596A1Method for manufacturing a preform for a wind turbine blade

Publication Date: 2025.02.13 LM WIND POWER AS

AI summary

The present invention relates to a method of manufacturing a part, such as a preform, for a wind turbine blade. One or more channel members (72) are fastened to the mould surface of a preform mould, and a fibre material (85) and a binding agent is arranged on the mould surface (87). The fibre material, the binding agent and the one or more channel members are covered with a vacuum bag, and negative pressure is applied to the fibre material and binding agent via the one or more channel members for consolidating the preform. Each of the channel members (72) comprises a plurality of slits (77) extending between its inner surface and its outer surface, the slits having an orientation that is substantially transverse to the longitudinal axis of the channel member.