Wind Turbine Blade Preform Adhesive Layer Porosity
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Solution Overview
Problem
Manufacturing preform parts for wind turbine blades with core materials and fiber reinforcement layers faces challenges in achieving adequate adhesion, leading to potential detachment during handling due to insufficient bonding.
Innovation Solution
A method involving a meltable adhesive sheet is used between the rigid core element and the fiber-based reinforcement structure, bonded by heating and cooling to create a partially porous adhesive layer for improved adhesion, allowing for even distribution and increased surface area for bonding, and enabling resin flow during the resin-injection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a powder binder is used to adhere components together, then the components can be immobilized, but the binder may agglomerate in the voids between fibers reducing adhesion effectiveness
Solution Approach 1:
The invention changes the physical state of the adhesive from powder to melt form. The adhesive is applied in molten state which allows it to flow and penetrate the fiber structure uniformly, then cooled to solidify and create strong bonds without agglomeration issues that plague powder binders
Solution Approach 2:
The adhesive sheet acts as an intermediary layer between the core material and fiber reinforcement. This intermediate adhesive layer provides a controlled bonding interface that ensures uniform adhesion throughout the composite structure, preventing the direct contact issues between core and fibers
2Reliability
If the adhesive layer is made continuous and non-porous to improve bonding surface, then adhesion increases, but resin flow during injection is blocked
Solution Approach 1:
The adhesive layer is designed with non-uniform local properties: it has adhesive bonding regions that provide strong bonding between layers, and porous channels distributed throughout that allow resin flow. This local differentiation of quality enables simultaneous achievement of strong adhesion and resin permeability
Solution Approach 2:
The adhesive layer is designed with a porous structure containing channels or voids that allow resin to flow through during the injection process. This porous architecture maintains bonding functionality while enabling efficient resin penetration throughout the preform part
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 method enhances the adhesion between the core and reinforcement structures, preventing detachment and facilitating the resin-injection process by ensuring a consistent and defined adhesive layer with high porosity for efficient resin penetration.
Implementation Method 1
Bonding the core element to the reinforcement structure by heating and subsequent cooling of the adhesive sheet
Implementation Method 2
Bonding the core element to the reinforcement structure by heating and subsequent cooling of the adhesive sheet
Implementation Method 3
bonding one or more rigid core elements to one or more reinforcement structures consisting of a fiber-based material by heating and subsequent cooling of at least one adhesive sheet of a meltable adhesive for creating an adhesive layer
Data Source
AI summary
A method for manufacturing a preform part for a wind turbine blade, includes the steps: providing at least one rigid core element, at least one reinforcement structure consisting of a fiber-based material and at least one adhesive sheet of a meltable adhesive, arranging the adhesive sheet in between the core element and the reinforcement structure, and bonding the core element to the reinforcement structure by heating and subsequent cooling of the adhesive sheet for creating an adhesive layer between the core element and the reinforcement structure, wherein the adhesive layer consists of the adhesive and is partially pervious for a liquid.