Container comprising fibre material for a fibre-reinforced composite component

Patent metadata

Field	Value
Publication number	US-12005653-B2
Application number	US-202017760592-A
Country	US
Kind code	B2
Filing date	Sep 15, 2020
Priority date	Sep 16, 2019
Publication date	Jun 11, 2024
Grant date	Jun 11, 2024

Abstract

The present invention relates to a container having a cavity, wherein the cavity has a cavity pressure and comprises fibre material suitable for manufacturing one or more fibre-reinforced composite components for a wind turbine blade, and at least a part of the fibre material touches a first part of a wall of the container, at least the first part of the wall consisting of a flexible airtight material, and a ratio of an entire volume of non-cured polymer in the cavity to an entire volume of the fibre material in the cavity is less than 0.3, and the container is adapted to prevent inflow of a polymer into the cavity. A method for preparing such a container is also disclosed. A method for laying fibre material into a mould is also disclosed.

First claim

The invention claimed is:

1. A method for providing a container comprising fibre material suitable for manufacturing one or more fibre-reinforced composite components for a wind turbine blade, the method comprising:
selecting an interchangeable preform ( 62 ) with a desired shape for shaping the fibre material ( 85 ) to the desired shape;
arranging the fibre material ( 85 ) on the interchangeable preform ( 62 ), the interchangeable preform ( 62 ) being supported on a board ( 61 );
forming a cavity by arranging a flexible airtight material ( 65 ) in contact with the board ( 61 ), the cavity surrounding the arranged fibre material ( 85 ) and the interchangeable preform ( 62 ); and
sealing off the cavity so as to prevent inflow of polymer into the cavity.

2. The method in accordance with claim 1 , further comprising:
reducing a pressure in the cavity below a threshold pressure of 800 hPa.

3. The method in accordance with claim 1 , further comprising a step of providing a non-cured polymer, wherein the cavity further surrounds the non-cured polymer, and wherein a ratio of an entire volume of the non-cured polymer in the cavity to an entire volume of the fibre material in the cavity is less than 0.3.

4. A method for laying up fibre material in a mould ( 21 ) having a mould surface ( 22 ), the method comprising:
providing a container ( 100 ) having a cavity, wherein the cavity has a cavity pressure and comprises fibre material ( 85 ) suitable for manufacturing one or more fibre-reinforced composite components for a wind turbine blade, and at least a part of the fibre material ( 85 ) touches a first part ( 65 ) of a wall ( 61 , 65 ) of the container, at least the first part ( 65 ) of the wall comprising a flexible airtight material ( 65 ), and the container is adapted to prevent inflow of a polymer into the cavity;
arranging the container on the mould surface and/or on material prearranged ( 91 ) on the mould surface, wherein the container is arranged such that the first part of the wall of the container is supported by the mould surface and/or by the prearranged material, and the fibre material is supported at least partly by the first part of the wall of the container;
allowing the cavity pressure to assume an ambient pressure surrounding the container; and
removing at least a part of the flexible airtight material from between the fibre material and the mould surface and/or the prearranged material, the removing being performed while at least part of the fibre material continues to be supported at least partly by the first part of the wall of the container.

5. The method in accordance with claim 4 , wherein the fibre material, prior to initiating removing the at least a part of the flexible airtight material, is supported only by the first part of the wall of the container.

6. The method in accordance with claim 4 , wherein the step of allowing the cavity pressure to assume the ambient pressure surrounding the container is initiated after initiating the step of arranging the container on the mould surface and/or on the prearranged material.

7. The method in accordance with claim 4 , wherein removing the at least a part of the flexible airtight material comprises sliding the flexible airtight material out from between the fibre material and the mould surface and/or the prearranged material.

8. The method in accordance with claim 4 , wherein removing at least a part of the flexible airtight material comprises rolling the flexible airtight material onto a roller between the fibre material and the mould surface and/or the prearranged material.

9. The method in accordance with claim 4 , wherein the mould ( 21 ) is a mould for a wind turbine blade part.

10. A container ( 100 ) having a cavity, wherein the cavity has a cavity pressure and comprises fibre material ( 85 ) suitable for manufacturing one or more fibre-reinforced composite components for a wind turbine blade, wherein at least a part of the fibre material ( 85 ) touches a first part ( 65 ) of a wall ( 61 , 65 ) of the container, at least the first part ( 65 ) of the wall consisting of a flexible airtight material ( 65 ), wherein the container is adapted to prevent inflow of a polymer into the cavity, and wherein the container ( 100 ) further comprises an interchangeable preform ( 62 ) such that the fibre material ( 85 ) is arranged on the interchangeable preform ( 62 ) to shape the fibre material ( 85 ) with a desired shape.

11. The container in accordance with claim 10 , wherein a static coefficient of friction of the flexible airtight material is 0.2 or lower.

12. The container in accordance with claim 10 , wherein the cavity pressure is maintained below a threshold pressure of 800 hPa.

13. The container in accordance with claim 12 , wherein the cavity is passively sealed off to maintain the cavity pressure below the threshold pressure.

14. The container in accordance with claim 12 , further comprising cavity evacuation means ( 71 , 72 ) in fluid communication with the cavity and configured to reduce the cavity pressure below the threshold pressure and to maintain the cavity pressure below the threshold pressure.

15. The container in accordance with claim 10 , wherein the cavity further comprises a non-cured polymer.

16. The container in accordance with claim 15 , wherein a ratio of an entire volume of cured polymer and non-cured polymer in the cavity to the entire volume of the fibre material in the cavity is less than 0.3.

17. The container in accordance with claim 15 , wherein a ratio of an entire volume of the non-cured polymer in the cavity to an entire volume of the fibre material in the cavity is less than 0.3.

18. The container in accordance with claim 10 , wherein the interchangeable preform ( 62 ) in the cavity is a non-planar preform.

19. The container in accordance with claim 10 , wherein the flexible airtight material is a vacuum bagging material.

20. A container ( 100 ) having a cavity, wherein the cavity has a cavity pressure and comprises fibre material ( 85 ) suitable for manufacturing one or more fibre-reinforced composite components for a wind turbine blade, wherein at least a part of the fibre material ( 85 ) touches a first part ( 65 ) of a wall ( 61 , 65 ) of the container, at least the first part ( 65 ) of the wall comprising a flexible airtight material ( 65 ), wherein the container is impermeable to polymer so as to prevent inflow of a polymer into the cavity, and wherein the container ( 100 ) further comprises an interchangeable preform ( 62 ) such that the fibre material ( 85 ) is arranged on the interchangeable preform ( 62 ) to shape the fibre material ( 85 ) with a desired shape.

Assignees

• Blade Dynamics Ltd

Inventors

• Todd Paul

Classifications

• B29C70/541

  Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement (positioning inserts in moulds B29C33/12; lay-up on a mould B29C70/30) · CPC title

• B29L2031/085

  Wind turbine blades · CPC title

• B29K2309/08

  Glass · CPC title

• B29K2307/04

  Carbon · CPC title

• B29C70/54

  Component parts, details or accessories; Auxiliary operations {, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing} · CPC title