Segmented Flow Media for Wind Turbine Resin Infusion
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Solution Overview
Problem
Existing methods for infusing resin into composite wind turbine rotor blades face challenges such as high viscosity of typical thermosetting resins, leading to slow infusion rates and potential defects, and require labor-intensive flow media installation and removal, which absorb resin and are difficult to discard.
Innovation Solution
The method involves placing high permeability flow media interleaf layers with dedicated resin feed lines in the laminate stack, allowing sequential and independent resin transfer into each layer, increasing pressure driving force and reducing fill time, while preventing defects with non-porous separation layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional flow media are used for resin infusion, then resin distribution is improved, but labor intensity and resin absorption increase
Solution Approach 1:
The flow medium is segmented into multiple discrete channels formed by alternating permeable and impermeable layers. Each channel acts as an independent resin distribution pathway, eliminating the need for single-piece flow media that require manual installation and removal. The segmented structure enables automated resin infusion while maintaining precise distribution control.
Solution Approach 2:
The patent introduces a multi-layered intermediate structure consisting of permeable and impermeable layers that mediate between the resin source and the fiber preform. This intermediate structure automatically distributes resin through capillary action and pressure gradients without requiring manual placement or removal of traditional flow media.
2Speed
If resin injection pressure is increased to overcome flow resistance, then infusion speed improves, but resin absorption by flow media increases
Solution Approach 1:
The patent employs porous permeable layers with controlled porosity and permeability characteristics. These layers allow resin to pass through efficiently while preventing excessive absorption. The porous structure provides capillary channels that guide resin flow without requiring high injection pressures, thereby reducing resin loss while maintaining infusion speed.
3Productivity
If permeability of fiber preform is increased to improve resin impregnation, then infusion rate improves, but structural integrity may be compromised
Solution Approach 1:
The fiber preform is segmented into multiple thin layers separated by alternating permeable and impermeable flow control layers. This segmentation increases the overall permeability of the preform stack by creating multiple parallel resin flow pathways, thereby improving infusion rate without compromising the structural integrity of individual fiber layers.
Solution Approach 2:
The patent introduces flow control in the thickness dimension by stacking multiple layers with alternating permeability. This dimensional approach creates through-thickness resin distribution pathways that enhance infusion rate while maintaining in-plane structural integrity of the composite laminate.
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 results in a 38% reduction in resin fill time and prevents infusion defects by maximizing pressure gradient and guiding resin flow effectively, enhancing the efficiency of the resin infusion process.
Implementation Method 1
The flow rate v (m/s) of a resin can be expressed as v = -K•ΔP/μ; where K denotes permeability, an index representing the easiness of impregnation into the reinforcing fiber base material with the resin, P denotes the pressure of the resin, and μ denotes the viscosity of the resin. In this formula, ΔP represents the pressure gradient.
Implementation Method 2
At least one of the plurality of flow media layers (54) is permeable to the resin (66), wherein at least one of the plurality of flow media layers (54) redirects a resin flow front (72) when the resin (66) is infused into the laminated structure (52).
Implementation Method 3
Then curing the transferred resin in the laminated structure to form a composite laminate component having the at least two reinforced layers, the plurality of interleaf layers, and cured resin.
Data Source
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AI summary
A wind turbine composite laminate component and method for producing it is disclosed as initially assembling a laminated structure having at least two reinforced layers and a plurality of interleaf layers positioned adjacent to one of the at least two reinforced layers. Then placing the laminated structure into a mold where resin is sequentially and independently transferred into each of the plurality of interleaf layers. Then curing the transferred resin in the laminated structure to form a composite laminate component having the at least two reinforced layers, the plurality of interleaf layers, and cured resin.