WO2004078442A1 - Preforme preconsolidee et procede de preconsolidation de preforme - Google Patents

Preforme preconsolidee et procede de preconsolidation de preforme Download PDF

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Publication number
WO2004078442A1
WO2004078442A1 PCT/EP2003/002292 EP0302292W WO2004078442A1 WO 2004078442 A1 WO2004078442 A1 WO 2004078442A1 EP 0302292 W EP0302292 W EP 0302292W WO 2004078442 A1 WO2004078442 A1 WO 2004078442A1
Authority
WO
WIPO (PCT)
Prior art keywords
resin
consolidated
epoxy
fibres
curing
Prior art date
Application number
PCT/EP2003/002292
Other languages
English (en)
Inventor
Anton Bech
Original Assignee
Vestas Wind Systems A/S
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Vestas Wind Systems A/S filed Critical Vestas Wind Systems A/S
Priority to PCT/EP2003/002292 priority Critical patent/WO2004078442A1/fr
Priority to AU2003218697A priority patent/AU2003218697A1/en
Priority to CA002517956A priority patent/CA2517956C/fr
Priority to AT03718782T priority patent/ATE355961T1/de
Priority to PT03718782T priority patent/PT1603735E/pt
Priority to DK03718782T priority patent/DK1603735T3/da
Priority to DE60312391T priority patent/DE60312391T2/de
Priority to PCT/EP2003/004171 priority patent/WO2004078461A1/fr
Priority to US10/548,060 priority patent/US7521105B2/en
Priority to EP03718782A priority patent/EP1603735B1/fr
Priority to ES03718782T priority patent/ES2282616T3/es
Priority to AU2003229708A priority patent/AU2003229708A1/en
Priority to AU2003222831A priority patent/AU2003222831B2/en
Priority to CNB038262290A priority patent/CN100393504C/zh
Priority to PCT/EP2003/004167 priority patent/WO2004078465A1/fr
Priority to EP03740159A priority patent/EP1603736B1/fr
Priority to PCT/EP2003/005630 priority patent/WO2004078462A1/fr
Priority to PT03740159T priority patent/PT1603736E/pt
Priority to CA002517966A priority patent/CA2517966C/fr
Priority to CNB038262401A priority patent/CN100471657C/zh
Priority to AU2003303991A priority patent/AU2003303991B2/en
Priority to US10/547,748 priority patent/US7731882B2/en
Priority to AT03740159T priority patent/ATE334802T1/de
Priority to DK03740159T priority patent/DK1603736T3/da
Priority to ES03740159T priority patent/ES2270058T3/es
Priority to DE60307326T priority patent/DE60307326T2/de
Publication of WO2004078442A1 publication Critical patent/WO2004078442A1/fr
Priority to US12/397,750 priority patent/US8409396B2/en
Priority to US12/795,017 priority patent/US8128854B2/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/116—Single bevelled joints, i.e. one of the parts to be joined being bevelled in the joint area
    • B29C66/1162—Single bevel to bevel joints, e.g. mitre joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/342—Preventing air-inclusions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/526—Joining bars
    • B29C66/5261—Joining bars for forming coaxial connections, i.e. the bars to be joined forming a zero angle relative to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B29C66/712—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition of the other part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72141—Fibres of continuous length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73111—Thermal expansion coefficient
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7375—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured
    • B29C66/73751—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being uncured, i.e. non cross-linked, non vulcanized
    • B29C66/73752—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being uncured, i.e. non cross-linked, non vulcanized the to-be-joined areas of both parts to be joined being uncured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7375—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured
    • B29C66/73753—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being partially cured, i.e. partially cross-linked, partially vulcanized
    • B29C66/73754—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being partially cured, i.e. partially cross-linked, partially vulcanized the to-be-joined areas of both parts to be joined being partially cured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
    • B29C66/73941—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset characterised by the materials of both parts being thermosets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/202—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/748—Machines or parts thereof not otherwise provided for
    • B29L2031/7504—Turbines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2363/00—Epoxy resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2603/00—Vanes, blades, propellers, rotors with blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/60—Properties or characteristics given to material by treatment or manufacturing
    • F05B2280/6003—Composites; e.g. fibre-reinforced
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2253/00—Other material characteristics; Treatment of material
    • F05C2253/04—Composite, e.g. fibre-reinforced
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the invention relates to fibre-reinforced composites.
  • the invention relates to a semi-manufacture comprising a partially cured resin and several layers of fibres.
  • US-patent 4,954,304 discloses a process for producing a prepreg using a double resin system with an epoxy-based system and a vinyl-based system.
  • the combination of two different systems may introduce compatibility problems.
  • US-patent 4,954,304 does not concern production of pre-forms with more than one layer (i.e. only prepregs).
  • pre-consolidated pre-forms that may be used for manufacture of reinforced composites.
  • Said pre-forms and composites pose good reproducibility, low porosity and good physical properties.
  • a pre-form is a composite material comprising fibres and - unless otherwise stated - an uncured resin.
  • the fibres are preferably provided in layers of oriented fibres like for example individual fibres, fibre tows, fibre tow-pregs or prepregs.
  • Fibres are advantageous compared to prepregs, since the individual fibres are less bounded and hence may rearrange easily.
  • individual fibres, fibre tows and tow-pregs are advantageous over prepregs in that they may be provided in the pre-form with a greater freedom, the price is lower as well as the amount of waste may be lower.
  • prepregs are advantageous in being readily available.
  • a pre-form may for example contain one or more of fillers (e.g. a cheap inert material) and/or solvents and/or diluents and/or rheological agents and/or viscosity adjusting agent.
  • fillers e.g. a cheap inert material
  • solvents and/or diluents and/or rheological agents and/or viscosity adjusting agent e.g. a cheap inert material
  • the advantage of using the pre-consolidation approach requires at least two layers of oriented fibres, however, the advantage will increase as the number of layers increases to for example 3, 4, 5, 8, 10, 15, 20, 50, 100 or more layers.
  • pre-consolidation is herein meant a process, whereby gas inside a pre-form is removed and a low porosity pre-form is produced.
  • Pre-consolidation involves redistribution of a resin and optionally a redistribution of fibres. Furthermore, pre- consolidation may involve a limited curing of the resin. Pre-consolidation is particularly useful as it produces a dense pre-form (hereinafter named a pre-consolidated preform).
  • Pre-consolidated pre-forms and composites prepared from pre-consolidated pre-forms will be appreciated amongst others due to good reproducibility, low porosity, high homogeneity, high strength, ability to plastically shaping of the pre-consolidated pre-form, ability to be connected to other pre-forms and/or other structures, suitability for automation and long shelf life without premature curing.
  • gas By gas is herein meant entrapped atmospheric air as well as gaseous products, by- products and starting materials related to the preparation process.
  • this limited curing may involve a release of up to 50% or the energy that will be released by a complete curing of the resin.
  • the extent of curing is limited to an extent that will allow the pre-form to be deformed plastically.
  • the degree of curing that will allow for plastically deformation of a pre-consolidated pre-form depends amongst others on the exact resin as well as on the fibre type and fibre content.
  • the limited curing involves less than about 20% of the energy that will be released by a complete curing of the resin and more preferably that the limited curing involves between 3 to 15 % of the energy that will be released by a complete curing.
  • the pre-consolidation process should reduce the porosity of a preform, however, it is preferred that the resulting porosity of the pre-consolidated preform is less than 5% by volume, preferably less than 2% by volume and more preferably less than 1% by volume. In some cases, a porosity of even 1% may reduce the properties of a composite considerably. In these cases, it will be appreciated that the method and the pre-consolidated pre-forms may be produced with porosities well below 1 %. For example, a reproduced porosity of about 0.2% by volume was realised for a composite with 60% carbon fibres in epoxy. The reduction of the porosity may for example be a result of exposing the pre-form to a pressure and/or a vacuum in relation to the pre-consolidation process.
  • the porosity of the pre-consolidated pre-form can not be established directly, as a density is not known and may vary throughout the material. Hence, the porosity should be established by optical method on a materialographic sample. Preparation of materialographic samples from an uncured pre-consolidated pre-form is very demanding, since the material comprises both a very soft element (i.e. a resin) and a very hard element (i.e. the fibre). To establish a reproducible result, it is hence necessary to cure the pre-form prior to materialographic preparation. This curing should be pressureless to ensure that the porosity is unaffected by the process. To ensure handleability the pre-consolidated pre-form should be substantially unsticky, i.e. it should be easily releasable from any relevant surface and it should not leave excessive amounts of resin on a surface when released.
  • pre-consolidated pre-forms are at least partially deformable. This may for example be realised through the balanced and limited curing during the pre-consolidation process.
  • at least a part of a pre-consolidated pre-form is capable of being bent around an axis parallel to the main fibre orientation with a diameter of more than 1 cm, however, in some cases a pre- consolidated pre-form may be bent with a diameter of more than 5 cm by plastic deformation.
  • the low bending diameters may be realised by rearranging of resin and/or fibres or by 3-dimensional forming of a pre-form.
  • 3-dimensional forming is herein meant that the thickness (e.g.
  • the number of layers or amount of fibres and/or resin) and/or the form of the ground plan is adjusted for a part of the pre-form relative to the bulk of the pre-form.
  • a part of the pre-consolidated pre-form is prepared for very sharp bending, whereas bending around an axis with larger diameters, e.g. 50 cm may often be realised by all parts of the pre-consolidated preform.
  • the stiffness of a pre-form realised during a pre-consolidation process should ensure that the pre-consolidated pre-form is stiff enough to prevent relaxation of the pre- consolidated pre-form in the length direction of the fibres when placed on a non-flat surface and yet allow for plastic deformation around an axis parallel to the length direction of the fibres.
  • a pre-consolidated pre-form comprising carbon fibres
  • the pre-consolidated pre-form should remain substantially flat during laying and curing, whereas the glass fibres should adjust to the shape/form of the pre-consolidated pre-form.
  • the carbon fibres will remain straight leading to increased strength of the combined structure.
  • the pre-consolidation process often leads to an increase in viscosity of the resin in the pre-form, for example by a partial curing. It is preferred that the viscosity at room temperature is increased by a factor of at least two and more preferably by a factor of at least five, as an increase in viscosity will enhance handleability, strength and unstickyness. In some cases, the viscosity may be increased by a much higher factor like for example 10, 100 or 1000. This is for example the case if part of the resin is injected into the pre-form as a room temperature liquid. Another way to express the increase in viscosity is to look at viscosity directly. It is preferred that the viscosity of the resin in the unconsolidated pre-form is between about 100 to 10,000 cP at the temperature where the pre-consolidation process is conducted, preferably between about 500 to 3,000 cP.
  • the temperature where the pre-consolidation process is conducted may vary considerably depending particularly on the composition of the resin. Typical the pre- consolidation temperatures for epoxy-based resin systems are 50 to 90°C and preferably 60 to 80°C, however, both higher and lower temperatures may be feasible in some systems.
  • the pre-consolidation process may lead to an increase in the glass transition temperature, T g , of the resin, for example by a partial curing. It is preferred that the T g of the resin is increased during pre-consolidation by at least 2°C and preferably by at least 5°C, as an increase in T g usually indicates an increase in the average molecular weight of the resin, which will enhance handleability, strength and unstickyness. In some cases, T g may be increased more. This is particularly the case when T g of the unconsolidated pre-form is very low.
  • a pre-consolidated pre-form according to the invention with an epoxy-based resin system should typically have a T g between -10 to +30°C and preferably a T g between -5 to 10°C.
  • T g of the resin of the pre-consolidated pre-form is higher than about 0°C and preferably higher than about 3°C.
  • T g of the resin should be below about 5°C and preferably below about 2°C.
  • the strength of a composite depends amongst others on the strength of the interface between the fibres and the matrix material (i.e. the cured resin). As the stiffness of the fibre is increased the sensitivity to the strength of the interface is also increased. Presence of porosity may weaken the interface but the actual effect of the porosity depends for example on the positioning and the size of the pores. Generally speaking, the greater the pores and the greater the amount of pores the worse. Another aspect is the wetting of the fibres. The difficulty in getting a good vetting of the fibres increases as the fibre diameter is decreased.
  • the processes and products of the present invention are particularly advantageous for pre-forms comprising thin and stiff fibres like for example carbon fibres, however, these processes and products are also superior to the prior art when other types of fibres are used as reinforcement like for example glass fibres, aramid fibres, synthetic fibres (e.g. acrylic, polyester, PAN, PET, PE, PP or PBO-fibres), bio fibres (e.g. hemp, jute, cellulose fibres etc.), mineral fibres (e.g. RockwoolTM), metal-fibres (e.g. steel, aluminium, brass, copper etc.) or boron fibres.
  • glass fibres aramid fibres
  • synthetic fibres e.g. acrylic, polyester, PAN, PET, PE, PP or PBO-fibres
  • bio fibres e.g. hemp, jute, cellulose fibres etc.
  • mineral fibres e.g. RockwoolTM
  • metal-fibres e.g. steel, aluminium,
  • the fibres may be a mixture of more than one type of fibres.
  • a combination of glass fibres and carbon fibres may be used.
  • the mixture may be homogenous with different concentrations in separate fibre layers or with different concentrations of fibres within any fibre layer.
  • Mixing of fibres may be advantageous since this opens for tailoring of material properties, for example from a combined stress/cost-perspective, or parts of a pre-form particularly suitable for connecting to other materials may be provided.
  • the fibres are primarily or exclusively carbon fibres.
  • carbon fibres is hereinafter meant fibres where the main component is carbon.
  • carbon fibres comprise fibres with graphite, amorphous carbon or carbon nano-tubes.
  • carbon fibres produced via for example a polyacrylonitril-route and a pitch-based route are comprised by this definition.
  • the resin may be a thermoplastic or a thermosetting resin, however, it is preferred that the pre-form comprises a thermosetting resin for reasons of chemical and thermal stability as well as ease of processing. It is further preferred that the resin is an epoxy- based or a polyester-based resin, most preferably an epoxy-based resin.
  • the resin may comprise more than one system, for example the resin may comprise two systems. These systems may be any combination of different or the same type of systems, however, it is preferred that the resin comprises two substantially epoxy- based systems.
  • the systems of a resin should be compatible.
  • two epoxy-based systems comprise a common component.
  • the common component may for example be a common catalyst, a common amine component or a common epoxy component, however, it is preferred that the common component is an epoxy component.
  • a resin comprising two epoxy-based systems with a common epoxy component may comprise an amine component of a first epoxy- based system that will react to the common epoxy component at a first relatively low temperature like for example below 50°C, preferably about room temperature.
  • a second epoxy-based system is preferably non-reactive or the reaction takes place at a very low rate. Since the reaction rate of the second epoxy- based system should be very low, it may advantageously be catalysed by a catalyst, which is un-active until activated. This activation may for example be by UV-light, addition of a compound or by heating, however, it is preferred that the catalyst is activated by heating.
  • a pre-form is placed on a reactor surface like for example a plate, a mould, etc. It is preferred that the reactor surface is flat and that it will withstand heating and/or vacuum. Then a pressure is applied on the pre-form.
  • the pressure may be applied by a press or - preferably - a vacuum within a vacuum enclosure. If a vacuum is used, then a vacuum enclosure should be obtained prior to pressing.
  • the vacuum enclosure may for example comprise a vacuum bag or it may comprise a reactor surface and a flexible cover connected in a vacuum tight way to the reactor surface. Gas may for example be evacuated through the reactor surface or through an opening in the vacuum bag or flexible cover.
  • the pre-consolidation is activated.
  • the activation may take place before and/or during and/or after applying of pressure.
  • the activation comprises a reduction of the viscosity of the resin. This may for example be realised by physical means (e.g. heating, addition of solvent, pressure etc.) and/or by a chemical reaction.
  • a limited curing may or may not take place.
  • the termination may for example be a result of exhaustion of a first resin system or cooling of the pre- consolidated pre-form to a temperature, where the curing reaction is sufficiently slow and/or the viscosity is sufficiently low for the pre-consolidated pre-form to achieve the stability needed for the desired shelf life.
  • the pre-form to be pre-consolidated is having at least one non-continuous layer of resin, through which gas may be removed during the pre- consolidation process.
  • the gas need not be removed from the pre-form in a plane of a layer of resin or in a plane of a layer of fibres.
  • the transportation distance and risk of having trapped gas inside the pre-consolidated pre-form is greatly reduced.
  • all layers of resin - optionally except from a layer on top of the top layer of fibres or below the bottom layer of fibres - are non-continuous.
  • An example of a method for securing that gas may continuously be removed from the pre-form during pre-consolidation involves a gradual activation of the pre-consolidation process starting either from the centre of the pre-form and moving towards the surfaces or from a side or edge and moving through the pre-form.
  • this may be realised by heating from the reaction surface only, hence activating gradually from the side of the pre-form in contact with the reaction surface or by controlled microwave heating, hence activating gradually from the inside of the pre-form and moving towards the surfaces.
  • Pre-forms according to the invention and provided by a method according to the invention are very useful for preparation of composite members by curing.
  • the pre-forms are highly useful for preparation of members for wind turbine blades and in particularly in spars in a wind turbine blade, since these composites fulfil the quality requirements and reproducibility requirements.
  • pre-forms When larger structures comprising pre-forms according to the invention or pre-forms produced by a method according to the invention are to be prepared, this may follow a method wherein the pre-form is shaped at least partially plastically.
  • the pre-form may be connected to one or more further pre-consolidated pre-forms and/or unconsolidated pre-forms before or after shaping to provide a larger structure.
  • the pre-form may also be connected to other structures. It is preferred but not required that the connections involve a tapered part or layers comprising a second type fibres.
  • the combined structure may be placed in a vacuum enclosure and provided with vacuum prior to curing. Finally, the pre-form structure is cured.
  • Fig. 1 shows a schematic cross sectional view of a pre-form.
  • Fig. 2 shows an image of a cross section in a pre-consolidated pre-form with fibre tows, which has been cured.
  • Fig. 3 shows an image of a cross section in a composite prepared from prepregs.
  • the properties of a laminar structure having layers of oriented fibres depend to a large extent on the distribution of the main elements of the structure resin, fibres and porosity.
  • the resin possesses a low strength compared to the fibres and may hence provide a route for crack propagation through the structure, if too large layers of resin are present.
  • Porosity may reduce the strength of the structure dramatically but the adversity depends on the size of pores, the shape and the distribution, i.e. the effect of small, isolated spherical pores is limited, whereas larger pores positioned in the interface between resin and fibres may be fatal to the structure. It is hence vital to be able to control the distribution of the elements.
  • the extent of redistribution depends i.a. on the viscosity of the resin during the compaction process, i.e. the lower the viscosity, the easier the redistribution of the elements.
  • the viscosity of the resin may be lowered more than what is feasible in the prior art, since the structure is not limited to support a particular shape during the process.
  • the pre-consolidation involves a limited curing of the resin, the viscosity may be further reduced since the curing increases the handleability and reduces the sticking of the pre-consolidated pre-form.
  • pre-consolidation allows for redistribution of resin and/or fibres to a much greater extent than what may be realised in the prior art.
  • the resulting pre- consolidated pre-forms may possess very low porosity as well as a more homogenous structure. This may for example result in a composite structure having a less pronounced laminar structure, i.e. where the layers are less pronounced, than a corresponding composite structure comprising only pre-forms that were not pre- consolidated prior to curing.
  • Fig. 1 an example of a schematic sectional view of a pre-form is shown indicating an example of the order of the components.
  • the distance between the layers would be much smaller and the resin and adhesive would usually be partially absorbed into the layers of fibres.
  • Layers of oriented fibres 2 are provided with an adhesive 6 between them.
  • Two layers of resin 4 are also shown.
  • the resin 4 is here distributed as a number of lines at an angle - here about orthogonal - to the layers of oriented fibres 2.
  • the resin hence is distributed in a non-continuous layer to allow for gas to escape from the pre-form orthogonal to the direction of the fibre tows.
  • the resin is provided between two layers of fibre tows. This is the preferred positioning of resin and when this positioning is used, it is highly desirable that the resin is distributed in non-continuous layers.
  • the resin may also be provided in contact with only one layer of fibre tows, i.e. in the top or at the bottom of the preform. In this case, it is preferred to provide the resin at the bottom of the pre-form and the resin may be provided in a continuous layer, as gas will not usually have to escape through the resin layer.
  • resin is only provided at top and the bottom of the pre-form, i.e. between the layers of fibres only adhesive is provided.
  • resin is only provided at the bottom of the pre-form, i.e.
  • Fig. 2 an image of a cross section in pre-consolidated pre-forms, which has been cured, is shown.
  • the pre-form comprises an epoxy resin and carbon fibre tows.
  • the image represents a section of about 1 x 1 mm and the image is typical for this sample.
  • the individual carbon fibres are seen as white dots in a grey matrix of cured epoxy resin.
  • the black dots and areas indicate porosity.
  • Four layers of fibres and three layers of resin are seen in the section shown in Fig. 2.
  • the resin layers are very vague as they are thin and fibres have migrated into the resin layers.
  • the approximate positions of the resin layers are therefore indicated by black lines to guide the eye. It is observed that the distribution of the elements in this section is highly homogeneous even if a high fibre content is present. Only a very low amount of porosity is observed and the porosity is dispersed as small isolated dots. Hence, very good properties including high strength and low standard deviations may be expected from this material.
  • a cross section of a composite prepared from prepregs are shown in Fig. 3. It is observed that the structure in Fig. 3 is highly laminar and that a much greater amount of porosity is present. Furthermore, the porosity is concentrated in the resin layers, which has been indicated by black lines to guide the eye. It is to be expected that the properties of this composite are poor compared to the composite shown in Fig. 2, particularly as the risk of laminar failure (i.e. delamination) is much greater for the composite shown in Fig. 3. Testing of the specimens confirmed this expectation.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Textile Engineering (AREA)
  • Thermal Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

L'invention concerne une préforme préconsolidée et un procédé de préconsolidation de préforme. On élimine le gaz présent dans une préforme pour donner une préforme de faible porosité, avec redistribution de résine et éventuellement redistribution de fibres. On peut aussi appliquer un durcissement limité à la résine. Les préformes préconsolidées et les composites élaborés à partir de ces préformes offrent entre autres les avantages suivants: bonne reproductibilité, faible porosité, homogénéité élevée, forte résistance, aptitude de la préforme consolidée à la mise en forme plastique, aptitude à la connexion avec d'autres préformes et/ou d'autres structures, aptitude à l'automation et longue durée de stockage sans traitement prématuré.
PCT/EP2003/002292 2003-03-06 2003-03-06 Preforme preconsolidee et procede de preconsolidation de preforme WO2004078442A1 (fr)

Priority Applications (28)

Application Number Priority Date Filing Date Title
PCT/EP2003/002292 WO2004078442A1 (fr) 2003-03-06 2003-03-06 Preforme preconsolidee et procede de preconsolidation de preforme
AU2003218697A AU2003218697A1 (en) 2003-03-06 2003-03-06 Pre-consolidated pre-form and method of pre-consolidating pre-forms
CNB038262290A CN100393504C (zh) 2003-03-06 2003-04-22 具有非兼容特征的复合材料之间的连接以及制备方法
AT03718782T ATE355961T1 (de) 2003-03-06 2003-04-22 Verbindung zwischen verbundteilen mit nichtkompatiblen eigenschaften und verfahren zur herstellung
PT03718782T PT1603735E (pt) 2003-03-06 2003-04-22 Conexão entre compostos com propriedades incompatíveis e método para a sua preparação
DK03718782T DK1603735T3 (da) 2003-03-06 2003-04-22 Forbindelse imellem kompositter med ikke-kompatible egenskaber samt fremgangsmåde til fremstilling
DE60312391T DE60312391T2 (de) 2003-03-06 2003-04-22 Verbindung zwischen verbundteilen mit nichtkompatiblen eigenschaften und verfahren zur herstellung
PCT/EP2003/004171 WO2004078461A1 (fr) 2003-03-06 2003-04-22 Connexion entre des composites ayant des proprietes non compatibles et procede de preparation
US10/548,060 US7521105B2 (en) 2003-03-06 2003-04-22 Connection between composites with non-compatible properties and method for preparation
EP03718782A EP1603735B1 (fr) 2003-03-06 2003-04-22 Connexion entre des composites ayant des proprietes non compatibles et procede de preparation
ES03718782T ES2282616T3 (es) 2003-03-06 2003-04-22 Conexion entre materiales compuestos con propiedades con compatibles y procedimiento de preparacion.
AU2003229708A AU2003229708A1 (en) 2003-03-06 2003-04-22 Wind turbine blade, spar for wind turbine blade and method of preparing these
AU2003222831A AU2003222831B2 (en) 2003-03-06 2003-04-22 Connection between composites with non-compatible properties and method for preparation
CA002517956A CA2517956C (fr) 2003-03-06 2003-04-22 Connexion entre des composites ayant des proprietes non compatibles et procede de preparation
PCT/EP2003/004167 WO2004078465A1 (fr) 2003-03-06 2003-04-22 Pale d'eolienne, longeron pour pale d'eolienne et leur procede e preparation
EP03740159A EP1603736B1 (fr) 2003-03-06 2003-05-28 Connexion entre organes
AT03740159T ATE334802T1 (de) 2003-03-06 2003-05-28 Verbindung zwischen bauteilen
PT03740159T PT1603736E (pt) 2003-03-06 2003-05-28 Ligação entre elementos
CA002517966A CA2517966C (fr) 2003-03-06 2003-05-28 Connexion entre organes
CNB038262401A CN100471657C (zh) 2003-03-06 2003-05-28 元件之间的连接
AU2003303991A AU2003303991B2 (en) 2003-03-06 2003-05-28 Connection between members
US10/547,748 US7731882B2 (en) 2003-03-06 2003-05-28 Connection between members
PCT/EP2003/005630 WO2004078462A1 (fr) 2003-03-06 2003-05-28 Connexion entre organes
DK03740159T DK1603736T3 (da) 2003-03-06 2003-05-28 Forbindelse imellem elementer
ES03740159T ES2270058T3 (es) 2003-03-06 2003-05-28 Conexion entre elementos.
DE60307326T DE60307326T2 (de) 2003-03-06 2003-05-28 Verbindung zwischen bauteilen
US12/397,750 US8409396B2 (en) 2003-03-06 2009-03-04 Connection between composites with non-compatible properties and method for preparation
US12/795,017 US8128854B2 (en) 2003-03-06 2010-06-07 Connection between members

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WO2009155921A1 (fr) * 2008-06-23 2009-12-30 Danmarks Tekniske Universitet Pale d'éolienne avec poutrelle oblique
WO2009155920A1 (fr) * 2008-06-24 2009-12-30 Danmarks Tekniske Universitet Pale d'éolienne renforcée
WO2010083921A2 (fr) * 2009-01-23 2010-07-29 Vestas Wind Systems A/S Préforme et longeron comprenant une structure de renforcement
WO2010083840A3 (fr) * 2009-01-21 2010-09-30 Vestas Wind Systems A/S Procédé de fabrication d'une pale d'éolienne par intégration d'une couche de résine durcie au préalable renforcée par des fibres
CN101223024B (zh) * 2005-07-15 2011-05-25 歌美飒创新技术公司 以复合材料为基础制造大型空心部件的方法
EP2363274A1 (fr) * 2010-03-04 2011-09-07 Rolls-Royce plc Procédé pour la fabrication d'un composant composite stratifié
WO2012092927A1 (fr) 2011-01-05 2012-07-12 Vestas Wind Systems A/S Préforme de stratifié pour pale de turbine éolienne
US20120195765A1 (en) * 2008-12-05 2012-08-02 Modular Wind Energy, Inc. Efficient wind turbine blades, wind turbine blade structures, and associated systems and methods of manufacture, assembly and use
US8454318B2 (en) 2006-12-15 2013-06-04 Bladena Aps Reinforced aerodynamic profile
US8485786B2 (en) 2007-01-16 2013-07-16 Bladena Aps Reinforced blade for wind turbine
US8632312B2 (en) 2007-01-25 2014-01-21 Bladena Aps Reinforced blade for wind turbine
EP2455609A3 (fr) * 2010-11-22 2014-04-30 Mitsubishi Plastics, Inc. Pale pour la production d'énergie éolienne et éolienne
US9416768B2 (en) 2009-12-02 2016-08-16 Bladena Aps Reinforced airfoil shaped body
CN106003876A (zh) * 2016-05-18 2016-10-12 中国电子科技集团公司电子科学研究院 一种防拉铆撕裂的复合材料及敷设方法
US9599094B2 (en) 2012-12-18 2017-03-21 Lm Wp Patent Holding A/S Method of manufacturing an aerodynamic shell part for a wind turbine blade
CN108700028A (zh) * 2015-12-23 2018-10-23 Lm Wp 专利控股有限公司 风力涡轮机叶片及相关制造方法

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Cited By (28)

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CN101223024B (zh) * 2005-07-15 2011-05-25 歌美飒创新技术公司 以复合材料为基础制造大型空心部件的方法
US8454318B2 (en) 2006-12-15 2013-06-04 Bladena Aps Reinforced aerodynamic profile
US8485786B2 (en) 2007-01-16 2013-07-16 Bladena Aps Reinforced blade for wind turbine
US8632312B2 (en) 2007-01-25 2014-01-21 Bladena Aps Reinforced blade for wind turbine
WO2009155921A1 (fr) * 2008-06-23 2009-12-30 Danmarks Tekniske Universitet Pale d'éolienne avec poutrelle oblique
WO2009155920A1 (fr) * 2008-06-24 2009-12-30 Danmarks Tekniske Universitet Pale d'éolienne renforcée
US9784240B2 (en) 2008-06-24 2017-10-10 Bladena Solutions Aps Reinforced wind turbine blade
US8807953B2 (en) 2008-06-24 2014-08-19 Bladena Aps Reinforced wind turbine blade
US9518558B2 (en) 2008-12-05 2016-12-13 Vestas Wind Systems A/S Efficient wind turbine blades, wind turbine blade structures, and associated systems and methods of manufacture, assembly and use
US8506258B2 (en) 2008-12-05 2013-08-13 Modular Wind Energy, Inc. Efficient wind turbine blades, wind turbine blade structures, and associated systems and methods of manufacture, assembly and use
US20120195765A1 (en) * 2008-12-05 2012-08-02 Modular Wind Energy, Inc. Efficient wind turbine blades, wind turbine blade structures, and associated systems and methods of manufacture, assembly and use
US8500409B2 (en) * 2008-12-05 2013-08-06 Modular Wind Energy, Inc. Efficient wind turbine blades, wind turbine blade structures, and associated systems and methods of manufacture, assembly and use
WO2010083840A3 (fr) * 2009-01-21 2010-09-30 Vestas Wind Systems A/S Procédé de fabrication d'une pale d'éolienne par intégration d'une couche de résine durcie au préalable renforcée par des fibres
US9073270B2 (en) 2009-01-21 2015-07-07 Vestas Wind Systems A/S Method of manufacturing a wind turbine blade by embedding a layer of pre-cured fibre reinforced resin
US10590909B2 (en) 2009-01-21 2020-03-17 Vestas Wind Systems A/S Method of manufacturing a wind turbine blade by embedding a layer of pre-cured fibre reinforced resin
WO2010083921A2 (fr) * 2009-01-23 2010-07-29 Vestas Wind Systems A/S Préforme et longeron comprenant une structure de renforcement
WO2010083921A3 (fr) * 2009-01-23 2010-11-18 Vestas Wind Systems A/S Préforme et longeron comprenant une structure de renforcement
US9416768B2 (en) 2009-12-02 2016-08-16 Bladena Aps Reinforced airfoil shaped body
EP2363274A1 (fr) * 2010-03-04 2011-09-07 Rolls-Royce plc Procédé pour la fabrication d'un composant composite stratifié
EP2455609A3 (fr) * 2010-11-22 2014-04-30 Mitsubishi Plastics, Inc. Pale pour la production d'énergie éolienne et éolienne
CN103402742B (zh) * 2011-01-05 2015-10-07 维斯塔斯风力系统有限公司 用于风轮机叶片的层压预制件
CN103402742A (zh) * 2011-01-05 2013-11-20 维斯塔斯风力系统有限公司 用于风轮机叶片的层压预制件
WO2012092927A1 (fr) 2011-01-05 2012-07-12 Vestas Wind Systems A/S Préforme de stratifié pour pale de turbine éolienne
US9579861B2 (en) 2011-01-05 2017-02-28 Vestas Wind Systems A/S Laminate pre-form for a wind turbine blade
US9599094B2 (en) 2012-12-18 2017-03-21 Lm Wp Patent Holding A/S Method of manufacturing an aerodynamic shell part for a wind turbine blade
CN108700028A (zh) * 2015-12-23 2018-10-23 Lm Wp 专利控股有限公司 风力涡轮机叶片及相关制造方法
CN108700028B (zh) * 2015-12-23 2021-08-24 Lm Wp 专利控股有限公司 风力涡轮机叶片及相关制造方法
CN106003876A (zh) * 2016-05-18 2016-10-12 中国电子科技集团公司电子科学研究院 一种防拉铆撕裂的复合材料及敷设方法

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