Patterned Fibre Fabrics for Wind Turbine Blade Preforms
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Solution Overview
Problem
The manufacturing of preforms for wind turbine blades, especially for large and complex shapes, is challenging due to poor drapability of fibre layers, leading to wrinkles and defects that affect the quality of the blade.
Innovation Solution
A method involving a preform mould where a stack of layers is formed, including patterned fabrics with alternating sections of fibre material with and without binding agent, which enhances drapability and reduces wrinkle formation during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fibre layers are used to form preforms for wind turbine blades, then the structural integrity and strength are improved, but the drapability of the fibre layers deteriorates, leading to wrinkle formation and defects
Solution Approach 1:
The fibre layer is segmented into multiple sub-layers with different properties. The first sub-layer comprises stiff fibres providing structural strength, while the second sub-layer comprises flexible fibres enabling drapability. This segmentation allows each sub-layer to perform its specific function, resolving the contradiction between strength and drapability.
Solution Approach 2:
Different regions of the fibre layer are assigned different fibre types and properties. The first sub-layer uses stiff fibres in regions requiring structural integrity, while the second sub-layer uses flexible fibres in regions requiring conformability to the mould surface. This local differentiation optimizes both strength and drapability simultaneously.
2Shape
If complex and curved surfaces are formed in the preform, then the blade geometry is improved, but the manufacturing time and complexity increase
Solution Approach 1:
The preform is pre-shaped and pre-consolidated in a preform mould before being placed in the final blade mould. The flexible fibres in the second sub-layer enable the preform to conform to complex curved surfaces during this preliminary shaping, reducing the time and effort required for final moulding while achieving the desired blade geometry.
Solution Approach 2:
The physical parameters of the fibre layer are changed during the manufacturing process. The flexible fibres in the second sub-layer allow the preform to be molded into complex shapes at elevated temperatures, and the stiff fibres in the first sub-layer provide dimensional stability during curing. This parameter change enables complex geometry formation without proportionally increasing manufacturing time.
3Stability of the object's composition
If binding agent is applied to all fibre material, then the layer cohesion is improved, but the drapability and wrinkle prevention deteriorate
Solution Approach 1:
The fibre layer is segmented into two sub-layers with different binding agent applications. The first sub-layer has binding agent applied to provide layer cohesion and structural stability, while the second sub-layer has reduced or no binding agent to maintain flexibility and drapability. This segmentation resolves the contradiction between cohesion and drapability.
Solution Approach 2:
The binding agent application is differentiated locally across the two sub-layers. The first sub-layer receives binding agent where cohesion is needed for structural integrity, while the second sub-layer has minimal or no binding agent where flexibility for drapability is critical. This local quality differentiation optimizes both properties simultaneously.
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 method significantly improves the quality of wind turbine blade preforms by increasing drapability, reducing wrinkle formation, and shortening layup time, resulting in improved structural integrity of the blades.
Implementation Method 1
one or more of the layers is formed by a fabric, preferably an elongate fabric, comprising a fibre material treated with a binding agent
Implementation Method 2
heating the stack of layers to form a preform
Implementation Method 3
A vacuum is typically used to draw resin material into a mould
Implementation Method 4
curing and/or hardening the resin in order to form the blade part
Data Source
AI summary
The present invention relates a method of manufacturing a wind turbine blade (10) part using a preform (98). A plurality of layers are arranged within a preform mould (90) to form a stack of layers, wherein one or more of the layers is formed by an elongate fabric (70) comprising a fibre material treated with a binding agent. The elongate fabric comprises an alternating pattern of first sections of fibre material free from binding agent and second sections of fibre material treated with binding agent.