Waved Wind Turbine Blade Web Without Thick Core Materials
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing web designs for wind turbine blades are bulky, costly due to the use of thick core materials, and require complex manufacturing processes that increase production time and costs.
Innovation Solution
A laminate structure web design with a waved profile manufactured using hand lay-up, resin transfer moulding, or vacuum infusion, eliminating the need for expensive core materials and simplifying the production process by allowing for easy implementation in existing facilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a sandwich structure with thick core material is used, then structural strength is improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent changes the geometric parameters of the web by introducing a waved profile with specific wavelength and amplitude characteristics. This geometric modification provides structural strengthening without requiring additional core material, thereby reducing weight while maintaining or improving structural strength.
Solution Approach 2:
The patent uses composite construction by combining fibrous material layers with resin matrix material to form a laminate structure. This composite approach creates a lightweight yet strong web structure that eliminates the need for heavy core materials while maintaining structural integrity.
2Strength
If a sandwich structure with thick core material is used, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the core material component from the traditional sandwich structure. By removing this expensive element and replacing it with a waved profile geometry and laminate construction, the manufacturing cost is significantly reduced while structural strength is maintained through the wave geometry and composite laminate design.
Solution Approach 2:
The patent changes the manufacturing approach by using hand lay-up or resin transfer moulding processes that are more cost-effective than conventional sandwich structure manufacturing. The waved profile is formed through moulding or layering processes that reduce material costs and simplify manufacturing procedures.
3Stability of the object's composition
If conventional core materials are used, then structural stability is improved, but production time increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the waved profile geometry during the moulding or lay-up process rather than assembling it later. The wave structure is created in advance as an integrated feature of the laminate, eliminating subsequent assembly steps and reducing overall production time while maintaining structural stability.
Solution Approach 2:
The patent merges the wave profile formation with the laminate construction process. The waved geometry and fibrous material layers are combined into a single integrated structure through the moulding or lay-up process, eliminating separate manufacturing steps and reducing production time while ensuring structural stability through the integrated design.
4Weight of moving object
If a waved profile is used, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent optimizes the wave profile parameters (wavelength, amplitude, and geometry) to achieve weight reduction while controlling manufacturing complexity. By carefully selecting and standardizing these geometric parameters, the waved profile can be manufactured using conventional moulding or lay-up processes without requiring overly complex tooling or procedures.
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 waved web design reduces weight and costs while providing structural stability, enabling fast and cost-effective production with improved quality and handling, eliminating the need for thick core materials.
Implementation Method 1
introducing a resin matrix material into the laminate of layers under vacuum or by hand
Implementation Method 2
curing the infused laminate of layers to form a web with a waved profile
Data Source
AI summary
A web (12) is produced by hand layup, resin transfer moulding or vacuum infusion. The web (12) comprises a waved profile (17) defining a plurality of crest and valleys, the stitching yarns (32) thereof may optionally be aligned with the direction of the crests. The web (12) comprises one or more integrated projecting flanges (26) defining a bonding surface for connection with the spar caps (11) of the wind turbine blade (5). This web saves weight and reduces costs. There is also a wind turbine blade (5) and a manufacturing method.