Segmented Fibre Structural Mat for Wind Turbine Blade Reinforcement
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Solution Overview
Problem
Existing wind turbine blades face challenges in maintaining rigidity and flexibility due to the limitations of single fibers in ensuring crease-free and wrinkle-free attachment, which affects their aerodynamic performance and manufacturing efficiency.
Innovation Solution
A structural mat comprising bonded fibres connected by a matrix and connection means, such as stitching, to form groups that are pre-cured and arranged in layers to provide enhanced stiffness and adaptability to complex blade geometries, reducing the risk of creasing and wrinkling during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If single fibres are used to reinforce the blade, then the blade can achieve flexibility, but it is virtually impossible to ensure no creases or wrinkles while the fibre is attached to the rest of the blade
Solution Approach 1:
The patent divides the fibre reinforcement into multiple groups of bonded fibres rather than using single fibres. Each group contains multiple fibres bonded together by a matrix material, which prevents individual fibres from creasing or wrinkling while maintaining flexibility. The groups are further connected by connection means to form a structured mat that can be reliably attached to the blade.
Solution Approach 2:
The patent uses composite materials by bonding multiple fibres together with a matrix material to form groups. This composite structure combines the flexibility of individual fibres with the dimensional stability of the bonded group, eliminating the creasing problem while preserving adaptability. The connection means further reinforce this composite structure for reliable attachment.
2Strength
If fibre groups are made larger to provide more stiffness, then the blade structure is reinforced, but the groups cannot adapt to the complex blade geometry
Solution Approach 1:
The patent segments the fibre reinforcement into multiple smaller groups rather than using one large group. This allows the blade structure to be reinforced through the collective stiffness of multiple groups while each individual group remains small enough to adapt to complex blade geometries. The connection means hold these groups together to provide cumulative stiffness.
Solution Approach 2:
The patent transitions from using single fibres (one-dimensional) to groups of bonded fibres (two-dimensional structure with width and depth). This dimensional change provides stiffness in multiple directions while keeping each group compact enough to conform to complex three-dimensional blade surfaces when multiple groups are distributed across the surface.
3Strength
If a stiff board of longitudinal extending fibres is used to reinforce the blade, then the blade rigidity is improved, but the board would have to be made with a low tolerance to fit the shell and would only fit a specific blade type
Solution Approach 1:
The patent divides the reinforcement structure into multiple separable fibre groups that can be independently positioned and attached. This segmentation allows the same mat design to be adapted to different blade types and geometries, unlike a single stiff board that requires low tolerance and fits only one specific blade type. The connection means hold the groups together while allowing overall configuration flexibility.
Solution Approach 2:
The patent creates a universal reinforcement solution where the mat of fibre groups can be applied to various blade types and geometries. The modular group structure with connection means provides a flexible platform that maintains rigidity enhancement while adapting to different blade configurations, making it multi-functional across different wind turbine applications.
Data Source
AI summary
The invention relates to a structural mat for reinforcing a wind turbine blade structure. The structural mat comprises two or more groups of bonded fibers, the fibers being bonded by a matrix substantially preventing relative movement of said fibers and wherein said groups are connected to each other by connection means limiting the relative movement of said groups. The invention further relates to a wind turbine blade and a method for manufacturing a wind turbine blade.