Wind Turbine Mould Integrated Heating System
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Solution Overview
Problem
Existing wind turbine blade moulds lack robust and controlled heating solutions that maintain efficiency and durability while ensuring repeatability and reproducibility of high-quality blade production, with stringent requirements for temperature control and thermal expansion management.
Innovation Solution
A glass-reinforced, thermally expansion-tolerable mould with an integrated heating system, featuring a carbon heating element network, heat distribution layer, glass composition layers, and a resin composition, which provides even heating and thermal management, and includes a heat-reflecting layer for enhanced efficiency and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a heating system is integrated into the mould to cure epoxy resins at controlled temperatures, then the curing quality and production efficiency are improved, but the mould structure becomes more complex and the risk of thermal damage to the mould increases
Solution Approach 1:
The heating elements are integrated directly into the mould structure by embedding them within the mould body during manufacturing. This merging of the heating system with the mould eliminates the need for separate external heating apparatus, reducing overall system complexity while maintaining effective temperature control for curing epoxy resins at the required 130°C
Solution Approach 2:
The mould structure serves multiple functions simultaneously: it provides the shaping cavity for the blade, acts as a thermal management system through integrated heating elements, and maintains structural integrity during the curing process. This multi-functionality reduces the need for additional specialized components
2Temperature
If the mould is heated to high temperatures for curing, then the epoxy resin cures properly, but the mould materials may degrade or suffer thermal expansion issues
Solution Approach 1:
The mould utilizes composite materials construction with layers including carbon fiber reinforced polymers and heat-resistant materials. This composite structure provides both the thermal conductivity needed for effective heating and the thermal stability required to withstand curing temperatures without degradation, maintaining mould durability through repeated thermal cycles
Solution Approach 2:
The heating system incorporates temperature control mechanisms that maintain the curing temperature within a precise range (±3°C) at the target 130°C. By controlling the thermal parameters and avoiding excessive temperature excursions, the mould materials are protected from thermal degradation while still achieving proper resin curing
3Temperature
If traditional heating methods are used, then heating can be achieved, but temperature distribution becomes uneven and quality consistency is compromised
Solution Approach 1:
The heating system is divided into multiple segmented heating zones or heating elements distributed throughout the mould structure. This segmentation allows for localized temperature control and ensures uniform heat distribution across the entire mould surface, preventing hot spots and ensuring consistent curing quality throughout the blade
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 solution enables precise temperature control within ±3°C, ensuring consistent quality and extended mould lifespan by accommodating thermal expansion and preventing chemical reactions, thus improving the curing and post-curing processes of wind turbine blades.
Implementation Method 1
applying at least one carbon heating network layer (16)
Implementation Method 2
applying a heat distribution layer (42)
Implementation Method 3
applying at least one glass network layer (18) upon the at least one carbon network layer (16)
Implementation Method 4
The solution enables precise temperature control within ±3°C, ensuring consistent quality and extended mould lifespan by accommodating thermal expansion and preventing chemical reactions
Data Source
Figure 1
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Figure 3~5
AI summary
The present invention provides a method of fabricating a mould 10 and the mould fabricated by such method. The mould 10 is fabricated by providing a support structure having a predefined shape; applying a heat distribution layer on the support structure; applying a heating element network upon the heat distribution layer; applying at least one glass composition layer 18 upon the heating element network; applying a resin composition 22 to each of the heating element network and the at least one glass composition layer; and integrating the heat distribution layer, heating element network, the at least one glass composition layer and the resin composition to form a mould unit.