Thermoplastic Thermoset Composite Interface Bonding

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Solution Overview

Problem

Wind turbine blades made from composite structures of thermoset and thermoplastic resins often exhibit inferior mechanical properties due to poor material properties or interface properties between the layers, leading to reduced mechanical performance.

Innovation Solution

Incorporating functional groups such as amines, carboxylic acids, and oxiranes into thermoplastic and thermoset resin elements to form stable covalent bonds at interfaces during curing, enhancing the connection and mechanical properties of the composite structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If thermoplastic elements are incorporated into thermoset resin composite structures, then processing capabilities are enhanced, but mechanical properties are degraded due to inferior interface properties between layers

Engineering Contradiction:

Improveprocessing capabilitiesVSAvoidmechanical properties

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies parameter changes by introducing functional groups (amines, carboxylic acids, oxiranes) into the thermoplastic material to modify its chemical properties. This enables the thermoplastic layer to form stable covalent bonds with the thermoset resin during curing, transforming the interface from a weak physical bond to a strong chemical bond, thereby resolving the mechanical property degradation while maintaining processing advantages

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a multi-layer composite structure combining thermoplastic and thermoset resin layers. By carefully selecting and combining these different material systems with complementary properties (thermoplastic for processing and thermoset for structural performance), the composite structure achieves both enhanced manufacturability and maintained mechanical strength

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If thermoplastic elements are incorporated into thermoset resin composite structures, then processing capabilities are enhanced, but interface properties between layers deteriorate

Engineering Contradiction:

Improveprocessing capabilitiesVSAvoidinterface properties

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent introduces functional groups as chemical intermediaries at the interface between thermoplastic and thermoset layers. These functional groups act as mediators that facilitate strong bonding between the two material systems, enabling the thermoplastic layer to chemically interact with the thermoset resin during curing and form a reliable, durable interface

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If reinforced resin material is used to provide high rigidity and resistance to torsion and fatigue, then mechanical performance is improved, but part weight increases

Engineering Contradiction:

Improverigidity and resistance to torsion and fatigueVSAvoidpart weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent employs composite materials by combining thermoplastic and thermoset resin layers in a multi-layer structure. The thermoplastic layers can be optimized for lower density and easier processing, while the thermoset layers provide the necessary structural strength and rigidity. This composite approach allows weight optimization while maintaining mechanical performance requirements

Inventive Principle:

Principle #40Composite materials

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

The improved interface strength and mechanical properties of the composite structure result in higher rigidity and resistance to delamination, enabling the production of wind turbine blades with enhanced performance and safety.

Implementation Method 1

the thermoset resin containing elements and the thermoplastic elements comprise functional groups at the interface which bond to each other when the composite structure is cured or hardened

Methodology Applied

Scientific EffectCovalent bonding: Chemical Bonding

Data Source

PatentUS10328676B2Composite structure

Publication Date: 2019.06.25 SIEMENS GAMESA RENEWABLE ENERGY AS

AI summary

A composite structure having a number of thermoset resin containing elements and a number of thermoplastic elements and at least one interface between the thermoset resin containing elements and the thermoplastic elements is provided. The thermoset resin containing elements and the thermoplastic elements have functional groups at the interface which bond to each other when the composite structure is cured and the functional groups are independently selected from amines, carboxylic acids, acid anhydrides, oxiranes, and derivatives thereof in their non-bonded condition. Additionally, a blade having such a composite structure is provided.