Wind Turbine Rotor Blade Curing via Dual-Side Heating
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Solution Overview
Problem
Existing methods for producing wind turbine rotor blade components face challenges due to the long process times required for resin systems to cure, as they undergo exothermic reactions that necessitate external heat, leading to inefficient and time-consuming curing processes.
Innovation Solution
A method where fibrous semi-finished products are impregnated with a resin system and heated from both sides using integrated and external heating means, allowing for a consistent process temperature between 60°C and 140°C to facilitate faster and more uniform curing, reducing the exothermic peak's impact and shortening the curing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external heat is supplied to cure resin systems after exothermic peak, then curing is completed, but process time becomes very long (up to 10 hours)
Solution Approach 1:
The resin system is preheated before infusion and the molds are preheated to optimal curing temperature. This preliminary heating action ensures that once the resin is infused, the curing process begins immediately at the correct temperature without requiring prolonged external heating, thus reducing total process time while ensuring complete curing.
Solution Approach 2:
The patent changes the temperature parameters throughout the process - preheating the resin and molds to specific temperatures, then maintaining optimal curing temperature through controlled external heating after the exothermic peak. This parameter optimization allows curing to proceed efficiently without excessive time requirements.
2Reliability
If resin systems with strong exothermic reaction are used, then curing reaction proceeds, but temperature control becomes difficult and process complexity increases
Solution Approach 1:
The resin system and molds are preheated before infusion to reduce the temperature differential during curing. This preliminary action lessens the severity of the exothermic peak by starting the reaction at a higher baseline temperature, making temperature control more manageable and reducing the complexity of the heating system required.
Solution Approach 2:
The patent modifies the temperature parameters by preheating both the resin and molds to specific temperatures before infusion. This parameter change reduces the exothermic temperature spike by starting the curing process closer to the final curing temperature, thereby simplifying the temperature control requirements.
3Ease of operation
If low process temperature (less than 60°C) is used for curing, then resin systems can be easily handled, but curing time extends significantly
Solution Approach 1:
The molds and resin are preheated to optimal curing temperatures before the infusion process. This preliminary heating eliminates the need for prolonged low-temperature curing, allowing the resin to cure quickly at higher temperatures once infused, thus reducing overall curing time while maintaining ease of operation through controlled temperature management.
Solution Approach 2:
The patent changes the curing temperature parameter from low (less than 60°C) to optimized higher temperatures through preheating. This parameter change accelerates the curing reaction significantly while the controlled heating system maintains ease of operation by automatically managing the temperature profile throughout the process.
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 enables the use of resin systems with lower exothermic development, allowing for faster and more efficient curing of wind turbine components, reducing the overall production time and improving the structural integrity of the rotor blades.
Implementation Method 1
heated by at least one first heating element, which is arranged, for example, integrated on or in the production mold, and additionally heated by at least one further heating element
Implementation Method 2
the resin systems used react in a strong exothermic reaction after they have been infused. Resin systems typically have a resin component and a hardener that mix and react exothermically during the infusion process
Data Source
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AI summary
The invention relates to a method for producing a fiber-reinforced component of a rotor blade of a wind turbine, in that at least one fiber-containing semi-finished product (2) is placed onto a contact surface (3) of a production mold (1) for the component to be produced, the fiber-containing semi-finished product (2) is soaked with resin or has already been soaked with resin at least in some areas, heat for curing is supplied to the areas of the fiber-containing semi-finished product (2) that are soaked with resin, wherein heat for curing is supplied to the areas of the fiber-containing semi-finished product (2) that are soaked with resin from at least two opposite sides.