Thermoset-Compatible Adhesive for Composite Layup Fixation
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Solution Overview
Problem
Current methods for manufacturing composite materials, such as wind turbine rotor blades, face challenges with fiber layer displacement and wrinkles due to inadequate fixation, leading to suboptimal laminate properties and costly repairs, and existing adhesives often interfere with the thermosetting resin process or require labor-intensive stitching.
Innovation Solution
A method using an adhesive with functional groups that react with thermoset resin, allowing for temporary fixation and subsequent incorporation into the laminate without compromising material properties, utilizing unsaturated polyester or vinylester resins that can be dissolved during the resin infusion process for optimal compatibility and reduced permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If stitching is used to attach fabric layers, then fiber placement stability is improved, but labor intensity increases and fiber structure is damaged
Solution Approach 1:
The patent replaces the mechanical stitching system with a chemical adhesive system. The adhesive is applied to the mold surface or fabric layers to provide temporary fixation during lay-up, eliminating the need for mechanical needles and threads that damage fiber structures and require high labor intensity.
Solution Approach 2:
The patent changes the state of the adhesive from solid/semisolid to liquid during application, allowing it to flow and bond smoothly without mechanical intervention. The adhesive starts in a applicability state (liquid or soft solid) and cures to a solid state, providing fixation without the mechanical damage of stitching.
2Stability of the object's composition
If conventional adhesives are used for attaching fabrics, then fixation is achieved, but resin wetting is interfered with and material properties are degraded
Solution Approach 1:
The patent uses an adhesive with specific chemical composition and curing characteristics that allow it to change from a temporary fixation state to a compatible state with the thermoset resin. The adhesive is formulated to be dissolved or chemically compatible with the resin system, ensuring that the final composite material properties are not degraded by the presence of the adhesive.
Solution Approach 2:
The adhesive acts as an intermediary substance that temporarily bonds fabrics to the mold or each other during lay-up, but is designed to be compatible with and dissolved by the thermoset resin. This intermediary role allows the adhesive to fulfill its temporary fixation function while not interfering with the final resin impregnation and curing process.
3Stability of the object's composition
If adhesive is applied to attach fiber layers, then fiber displacement is prevented, but adhesive compatibility with thermoset resin is compromised
Solution Approach 1:
The patent formulates the adhesive with specific chemical parameters (composition, molecular weight, curing characteristics) that allow it to change its properties during the manufacturing process. The adhesive starts in a state that provides good fixation and ends in a state that is compatible with the thermoset resin, achieving both fixation and compatibility through controlled parameter changes.
Solution Approach 2:
The adhesive is designed as a composite material system that includes components compatible with both the fiber reinforcement and the thermoset resin. This composite adhesive formulation allows it to bond to different materials while remaining compatible with the final resin system, solving the compatibility problem.
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 prevents fiber displacement and wrinkles, enhancing laminate quality and properties while allowing for efficient and cost-effective production by ensuring compatibility with thermoset resins and reducing material permeability for improved vacuum assistance in composite manufacturing.
Implementation Method 1
an adhesive with functional groups, which can react with a thermoset resin
Implementation Method 2
at least partly dissolving the adhesive during wetting the adhesive with a thermoset resin containing components acting as solvents for the adhesive
Implementation Method 3
ensuring compatibility with thermoset resins and reducing material permeability for improved vacuum assistance in composite manufacturing
Data Source
AI summary
A method for manufacturing a composite using an adhesive for attaching different layers of fiber material in a correct position is provided. The method includes at least partly dissolving the adhesive by wetting the adhesive with a thermoset resin containing components acting as solvents for the adhesive. The adhesive may include a thermoplastic adhesive with functional groups, which can react with a thermoset resin. Preferably, the adhesive can be made from the same base resin as the thermoset resin for optimal compatibility. Moreover, the adhesive can also be used to reduce the permeability of a material, for example of a fiber package for handling using a semi-vacuum.