UV-IR Curing System for Wind Blade Composite Laminates
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Solution Overview
Problem
Current methods for manufacturing and repairing wind turbine rotor blades are time-consuming, labor-intensive, and costly due to issues like sagging, dimensional distortion, and low interlaminar strength caused by conventional curing techniques, which are impractical for large blades and require specialized facilities.
Innovation Solution
A combination UV-IR curing system using dual radiation sources to heat and cure composite layers simultaneously, forming covalent bonds across interfaces and achieving uniform curing throughout the thickness of the composite structure, optimizing glass transition temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional autoclave or oven curing is used to cure multiple layers simultaneously, then adhesion between layers is good, but sagging and dimensional distortion occur during compaction
Solution Approach 1:
The curing process is segmented into two distinct stages: first UV irradiation to cure the resin and solidify the structure, then IR heating to remove volatiles and complete the curing. This segmentation allows each stage to address specific requirements without compromising the other, preventing dimensional distortion while maintaining adhesion.
Solution Approach 2:
UV irradiation is applied first to preliminarily cure the resin and establish structural integrity before IR heating is applied. This preliminary action prevents sagging during the subsequent heating stage by already solidifying the composite structure.
2Manufacturing precision
If sequential curing of layers is used to avoid sagging, then dimensional stability is improved, but interlaminar strength decreases due to weak secondary adhesive bonds
Solution Approach 1:
The patent merges UV and IR curing methods into a single integrated process. UV irradiation provides rapid initial curing to establish dimensional stability, while IR heating subsequently removes volatiles and completes the curing, ensuring both dimensional stability and high interlaminar strength are achieved simultaneously.
3Productivity
If UV curing alone is used for fast laminate curing, then curing speed is improved, but glass transition temperature and complete curing of thick laminates cannot be achieved
Solution Approach 1:
The curing process is segmented into two distinct stages: first UV irradiation to cure the resin and solidify the structure, then IR heating to remove volatiles and complete the curing. This segmentation allows each stage to address specific requirements without compromising the other, preventing dimensional distortion while maintaining adhesion.
Solution Approach 2:
The patent changes the energy parameters applied to the composite material by using two different radiation types. UV irradiation provides high-energy photons for rapid polymerization, while IR heating provides thermal energy for volatile removal and completion of curing, achieving both speed and high glass transition temperature.
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 reduces manufacturing and repair cycle times, decreases costs, and enhances the strength and durability of composite structures by ensuring complete curing and high glass transition temperatures, making it suitable for large wind turbine blades.
Implementation Method 1
a first radiation source configured to heat a plurality of layers of a composite structure throughout a thickness of the plurality of layers of the composite structure
Implementation Method 2
a second radiation source configured to cure the plurality of pre-heated layers of the composite structure through a thickness of the composite structure
Data Source
AI summary
A UV-IR combination curing system and method for manufacture and repair of composite parts, such as for use in wind blade manufacture and repair. The system and method utilize UV and IR dual radiation sources to cure glass fiber reinforced laminates containing a photo initiator. The UV and IR dual radiation sources can be configured as discrete stand-alone UV and IR lamps used in a side by side configuration, a plurality of UV lamps with thermal IR radiation, a combined UV/IR lamp, or other forms of light sources providing both UV and IR radiation. To achieve high glass transition and complete curing of thick laminates, the IR radiation source is initially turned on to heat the laminate to close to 40° C.-100° C. before the UV radiation source is turned on. The IR radiation source can be turned off after UV radiation source is activated.