METHOD OF PRODUCING A COMPOSITE STRUCTURE VIA INTERMEDIATE PRODUCTS, THE RELATED APPARATUS AND A COMPOSITE STRUCTURE OBTAINABLE BY THE METHOD

• US 20100304170A1
• Filed: 08/22/2008
• Published: 12/02/2010
• Est. Priority Date: 09/04/2007
• Status: Active Grant

• Current Assignee: LM Glasfiber A/S (GE Aerospace)
• Original Assignee: LM Glasfiber A/S (GE Aerospace)
• Inventors: Frederiksen, Henrik
• Granted Patent: US 9,221,219 B2
• Time in Patent Office: Days
• US Class Current: 428/542.8
• CPC Class Codes: B29C 2791/001 Shaping in several steps
• CPC Class Codes: B29C 2791/006 Using vacuum
• CPC Class Codes: B29C 35/02 Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mouldcold vulcanisation B29C35/18 ; vulcanising tyres, presses therefor B29D30/0601
• CPC Class Codes: B29C 65/00 Joining or sealing of preformed parts , e.g. welding of plastics materials; Apparatus therefor general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326
• CPC Class Codes: B29C 65/40 Applying molten plastics, e.g. hot melt using welding bar combined with hot gases B29C65/12; by moulding B29C65/70
• CPC Class Codes: B29C 65/42 between pre-assembled parts B29C65/605 takes precedence
• CPC Class Codes: B29C 65/70 by moulding using a particular moulding technique, see the relevant technique , e.g. by injection B29C45/14467
• CPC Class Codes: B29C 66/1142 Single butt to butt joints
• CPC Class Codes: B29C 66/1162 Single bevel to bevel joints, e.g. mitre joints
• CPC Class Codes: B29C 66/14 the joint having the same thickness as the thickness of the parts to be joined B29C66/1142 takes precedence
• CPC Class Codes: B29C 66/54 Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/721 Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/7212 characterised by the composition of the fibres
• CPC Class Codes: B29C 66/72141 Fibres of continuous length
• CPC Class Codes: B29C 66/73754 the to-be-joined areas of both parts to be joined being partially cured
• CPC Class Codes: B29C 66/73921 characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/73941 characterised by the materials of both parts being thermosets
• CPC Class Codes: B29C 66/81455 being a fluid inflatable bag or bladder, a diaphragm or a vacuum bag for applying isostatic pressure inflatable element positioned between the joining tool and a backing-up part B29C66/82421
• CPC Class Codes: B29C 69/004 making articles by joining parts moulded in separate cavities, said parts being in said separate cavities during said joining B29C45/006, B29C51/267 take precedence
• CPC Class Codes: B29C 70/304 : In-plane lamination by juxtaposing or interleaving of plies, e.g. scarf joining
• CPC Class Codes: B29C 70/443 : and impregnating by vacuum or injection
• CPC Class Codes: B29K 2031/00 : Use of polyvinylesters or derivatives thereof as moulding material
• CPC Class Codes: B29K 2063/00 : Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2101/10 : Thermosetting resins
• CPC Class Codes: B29K 2101/12 : Thermoplastic materials
• CPC Class Codes: B29K 2105/06 : containing reinforcements, fillers or inserts
• CPC Class Codes: B29K 2105/24 : crosslinked or vulcanised
• CPC Class Codes: B29K 2301/00 : Use of unspecified macromolecular compounds as reinforcement use of unspecified rubbers B29K2221/00
• CPC Class Codes: B29K 2307/00 : Use of elements other than metals as reinforcement
• CPC Class Codes: B29K 2307/04 : Carbon
• CPC Class Codes: B29K 2309/08 : Glass
• CPC Class Codes: B29L 2031/082 : Blades, e.g. for helicopters
• CPC Class Codes: B29L 2031/085 : Wind turbine blades
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product

Abstract

A method of producing a composite structure comprising fibre reinforced material and having a longitudinal direction is described. The method comprises the following steps: a) manufacturing a first structure comprising a first cured composite part having a first thickness and a longitudinal direction with a first end, and a number of first fibre layers extending from the first end, b) manufacturing a second structure comprising a second cured composite part having a second thickness and a longitudinal direction with a second end, and a number of second fibre layers extending from the second end, and c) arranging the first structure and the second structure so that the first end faces towards the second end, and arranging the first fibre layers and the second fibre layers so that at least a part of the first fibre layers overlap at least a part of the second fibre layers in the longitudinal direction, d) supplying liquid resin in order to impregnate the first fibre layers and the second fibre layers, and e) curing the liquid resin in order to form the composite structure comprising the first cured composite part, the second cured composite part, and an intermediate composite part including the first fibre layers and the second fibre layers.

Claims

1-21. -21. (canceled)

22. A method of producing a wind turbine blade comprising fibre reinforced material and having a longitudinal direction, wherein the method comprises the following steps:

at a first site;

a) manufacturing a first structure comprising a first cured composite part having a first thickness and a longitudinal direction with a first end, and a number of first fibre layers extending from the first end,

at a second site;

b) manufacturing a second structure comprising a second cured composite part having a second thickness and a longitudinal direction with a second end, and a number of second fibre layers extending from the second end, and

at a third site being remote from the first and the second site;

c) arranging the first structure and the second structure so that the first end faces towards the second end, and arranging the first fibre layers and the second fibre layers so that at least a part of the first fibre layers overlap at least a part of the second fibre layers in the longitudinal direction,

d) supplying liquid resin in order to impregnate the first fibre layers and the second fibre layers, and

e) curing the liquid resin in order to form the composite structure comprising the first cured composite part, the second cured composite part, and an intermediate composite part including the first fibre layers and the second fibre layers.

23. A method according to claim 22, wherein the first site is in the proximity of the second site.

24. A method according to claim 22, wherein step a) involves the following steps:

I) providing a forming structure comprising a mould cavity and having a longitudinal direction,

II) placing fibre material in the mould cavity so that a part of the fibre material is arranged in a part corresponding to the first cured composite part of the first structure and another part of the fibre material forms the first fibre layers,

III) providing a resin in the mould cavity simultaneously with and/or subsequently to step b) in the part corresponding to the first cured composite part of the first structure, and

IV) curing the resin in order to form the first cured composite structure.

25. A method according to claim 24, wherein the fibre material is arranged so that the first fibre layers extend in the longitudinal direction beyond the mould cavity of the forming structure.

26. A method according to claim 22, wherein the first cured composite structure and the second cured composite structure are manufactured as shell members having an interior surface and an exterior surface.

27. A method according to claim 26, wherein the method comprises the steps of:

i) providing a first mould part comprising a first sealing means for sealing against the interior surface of the first shell part, and a second sealing means for sealing against the interior surface of the second shell part, and

ii) providing a second mould part comprising a first sealing means for sealing against the exterior surface of the first shell part, and a second sealing means for sealing against the exterior surface of the second shell part, and wherein steps d) and e) are carried out by use of the first mould part and the second mould part.

28. A method according to claim 27, wherein the first mould part and/or the second mould part are provided with a resin inlet.

29. A method according to claim 28, wherein the first mould part and/or the second mould part are provided with a vacuum outlet.

30. A method according to claim 27, wherein the first mould part and/or the second mould part comprise an inflatable part.

31. A method according to claim 22, wherein the first structure and the second structure in step c) are arranged so that surfaces of the first structure and the second structure substantially flush with each other.

32. A method according to claim 22, wherein the first end and/or the second end are angled so that the first thickness and/or the second thickness vary in the longitudinal direction.

33. A method according to claim 22, wherein the first fibre layers are cut so that ends thereof in step c) extend substantially to the second end and/or the second fibre layers are cut so that ends thereof extend substantially to the first end.

34. A method according to claim 22, wherein the first fibre layers and/or the second fibre layers are cut in an angle so that the thickness of the respective layers vary in the longitudinal direction.

35. A method according to claim 22, wherein the first fibre layers and/or the second fibre layers are cut so that ends thereof form a serrated boundary.

36. A method according to claim 22, wherein the first fibre layers in step c) are arranged such that a part of these defines one surface of the intermediate composite part, and the second fibre layers are arranged such that a part of these defines another surface of the intermediate composite part.

37. A method according to claim 22, wherein the intermediate composite part forms a local thickening of the composite structure.

38. A blade shell part (110;

160) comprising a cured composite part (112;

162) comprising fibre reinforced polymer and having a first end (113;

163), from which a number of fibre layers (114;

164) extend.

39. A blade according to claim 38, wherein the fibre layers (114;

164) extend loosely from the first end (113;

163).