WO2006058541A1 - Method and apparatus for producing fibre composite mouldings by means of vacuum infusion - Google Patents

Method and apparatus for producing fibre composite mouldings by means of vacuum infusion Download PDF

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Publication number
WO2006058541A1
WO2006058541A1 PCT/DK2005/000766 DK2005000766W WO2006058541A1 WO 2006058541 A1 WO2006058541 A1 WO 2006058541A1 DK 2005000766 W DK2005000766 W DK 2005000766W WO 2006058541 A1 WO2006058541 A1 WO 2006058541A1
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WO
WIPO (PCT)
Prior art keywords
vacuum
channels
source
mould
polymer
Prior art date
Application number
PCT/DK2005/000766
Other languages
French (fr)
Inventor
Axel Liebmann
Original Assignee
Lm Glasfiber 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
Priority to BRPI0518697A priority Critical patent/BRPI0518697B1/en
Priority to MX2007006325A priority patent/MX2007006325A/en
Priority to EP05809241.2A priority patent/EP1819502B1/en
Priority to AU2005312178A priority patent/AU2005312178B2/en
Priority to DK05809241.2T priority patent/DK1819502T3/en
Priority to US11/791,710 priority patent/US7939001B2/en
Application filed by Lm Glasfiber A/S filed Critical Lm Glasfiber A/S
Priority to CN200580047437XA priority patent/CN101124079B/en
Priority to JP2007543708A priority patent/JP4921380B2/en
Priority to CA2588849A priority patent/CA2588849C/en
Publication of WO2006058541A1 publication Critical patent/WO2006058541A1/en
Priority to NO20073381A priority patent/NO339058B1/en
Priority to AU2010236084A priority patent/AU2010236084B2/en

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Classifications

    • 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
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • 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
    • B29C70/546—Measures for feeding or distributing the matrix material in the reinforcing structure
    • 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
    • B29C70/36—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 and impregnating by casting, e.g. vacuum casting
    • 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
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
    • 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
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • 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
    • 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
    • B29C70/546—Measures for feeding or distributing the matrix material in the reinforcing structure
    • B29C70/548—Measures for feeding or distributing the matrix material in the reinforcing structure using distribution constructions, e.g. channels incorporated in or associated with the mould
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D15/00—Transmission of mechanical power

Definitions

  • the invention relates to a method according to the preamble of claim 1 and to an apparatus according to the preamble of claim 9.
  • the invention relates to a method and an apparatus for producing fibre composite mouldings by means of VARTM (vacuum assisted resin transfer moulding), where liquid polymer, also called resin, is filled into a mould cavity, in which fibre material priorly has been inserted, where a vacuum is generated in the mould cavity hereby drawing in the polymer. Often a minor positive pressure is generated at the inlet side in order to improve the filling therein of polymer.
  • VARTM vacuum assisted resin transfer moulding
  • Vacuum infusion is a process used for moulding fibre composite mouldings, where uniformly distributed fibres, said fibres being rovings, i.e. bundles of fibre bands, bands of rovings or mats, which are either felt mats made of in- dividual fibres or woven mats made of fibre rovings, are layered in one of the mould parts.
  • the second mould part is often made of resilient vacuum bag, and is subsequently placed on top of the fibre material. By generating a vacuum, typically 80 to 90% of the total vacuum, in the mould cavity between the inner side of the mould part and the vacuum bag, the liquid polymer can be drawn in and fill the mould cavity with the fibre material contained herein.
  • distribution layers or distribution tubes also called inlet channels, are used between the vacuum bag and the fibre material in order to obtain as sound and efficient a distribution of polymer as possible.
  • the polymer applied is polyester or epoxy
  • the fibre reinforcement is most often based on glass fibres or carbon fibres.
  • a vacuum said vacuum in this con- nection being understood as a negative pressure, is generated via the vacuum channels in the mould cavity, whereby liquid polymer is drawn into the mould cavity via the inlet channels in order to fill said mould cavity. From the inlet channels the polymer disperses in the mould cavity as a flow front moves towards the vacuum channels.
  • dry spots are areas where the fibre material is not impregnated, and where there can be air pockets, which are difficult or impossible to remove by controlling the vacuum pressure and possibly an overpressure at the inlet side.
  • the dry spots can be repaired after the process of filling the mould by for example puncturing the cloth in the respective location and by drawing out air for example by means of a syringe needle.
  • Liquid polymer can optionally be injected in the respective location, and this can for example be done by means of a syringe needle as well. This is a time-consuming and tiresome process.
  • DE 199 22 850 discloses an apparatus for producing fibre composite mouldings.
  • the apparatus includes a mould part, where the channels extend in the longitudinal direction of the apparatus below the moulding surface, and where the channels are connected to said surface through bores or longitudinal slots.
  • a plurality of valve members communicating with a vacuum source and a resin source, respectively, is placed at each end of the channels. Every second channel communicates with the vacuum source, and every second channel communicates with the resin source, and by time varying the setting of the valve members the flow front of the resin can be controlled during the impregnation process.
  • the object of the invention is to provide a method and an apparatus avoiding these draw-backs.
  • this object is achieved by periodically interrupting the connection of one or more of the inlet channels to the polymer source during the process of filling the mould, and by connecting said inlet channel or inlet channels to a vacuum source, so that liquid polymer in the mould cavity is drawn into the direction of said inlet channels, and/or by periodically interrupting the connection of one or more of the inlet channels to the vacuum source during the process of filling the mould, and by connecting said vacuum channel or channels to a polymer source, so that liquid polymer is drawn into the mould cavity through said vacuum channel or channels.
  • the vacuum channels and the inlet channels have one function only, as the vacuum channels draw air out of the mould cavity, and the inlet channels direct liquid polymer into the mould cavity.
  • Periodically allowing the inlet channels or the vacuum channels to have the reverse function according to the invention results in much greater flexibility. If, for example, a dry spot has occurred adjacent an inlet channel, a vacuum can be generated in said inlet channel, thus drawing the polymer around the dry spot in the direction of the respective inlet channel and pressing the dry spot into the same direction thus impregnating the area. Due to a pressure drop which increases with the distance from the vacuum channel, it can be difficult to remove dry spots found at a large dis- tance from a vacuum channel.
  • the mould cavity is formed by a solid mould part and a resilient vacuum bag.
  • the invention is particularly suitable for this type of mould as the use of a vacuum bag includes a particular risk of leaks.
  • the inlet channels and/or vac- uum channels are placed against the vacuum bag.
  • the inlet channels and/or vacuum channels are shaped as oblong hollow profile bodies, the interior of which communicates with the interior of the mould cavity through one or more slots extending in the longitudinal direction of the profile body.
  • the slot or the slots in one or more of the oblong hollow profile bodies are covered by a semipermeable membrane admitting air, but not admitting liquid polymer, and which are only partly fixed to the profile body.
  • the membrane can be fixed on one side of the slot but not on the other side of the slot.
  • the profile body obtains the function of a "flap valve", as the profile body allows for the discharge of liquid polymer when applied as an inlet channel, because one side of said membrane is pressed away from the pro- file body, or because the profile body is pressed away from the membrane thus creating an opening between the membrane and one side of the profile body.
  • the body produced is an oblong shell member, where the oblong profile bodies extend substantially parallel in the longitudinal direction of the shell member, the process of filling the mould starting with a plurality of the inlet channels communicating with the vacuum source.
  • the process of filling the mould starts with one or more of the centrally placed inlet profile bodies communicating with the polymer source as the flow front moves from the polymer source in the direction of the longitudinal sides of the shell member.
  • the process of filling the mould starts with one or more of the centrally placed inlet profile bodies communicating with the polymer source as the flow front moves from the polymer source in the direction of the longitudinal sides of the shell member.
  • the body is a blade shell half or a complete blade shell for a blade of a wind turbine.
  • the apparatus includes a mould with a mould cavity, a polymer source for liquid polymer, a plurality of inlet channels, which are connected to the mould cavity and via valve members are connected to the polymer source, a vacuum source, a plurality of vacuum channels, which are connected to the mould cavity and via valve members are connected to the vacuum source, characterized in that one or more of the inlet channels by means of valve members also are connected to a vacuum source, and/or that one or more of the vacuum channels via valve members also are connected to the polymer source.
  • Fig. 1 is a sectional view along line l-l in Fig. 2 through a mould for the production of a blade shell half
  • Fig. 2 is a schematic view of an apparatus for carrying out the method according to the invention
  • Fig. 3 shows a valve body included in the apparatus shown in Fig. 2,
  • Fig. 4 is a sectional view through an inlet profile body in a state, where it communicates with a vacuum source, and
  • Fig. 5 is a sectional view through the inlet profile body shown in Fig. 3 in a state, where it communicates with a polymer source.
  • Fig. 1 is a sectional view through a mould for the production of a blade shell half for a blade of a wind turbine by vacuum infusion and shows a solid mould part 1 with a top side mating to the exterior top side of the completed blade shell half.
  • a fibre insertion 14 of for example glass fibre or carbon fibre is placed on the inner top side of the mould part 1.
  • a tear-off layer 15 is placed which can be a net or a perforated film, and on top of the tear-off layer 15 a distribution net or a flow layer 16 is placed.
  • On top of the distribution net / flow layer 16 a plurality of ⁇ -shaped inlet pro- file bodies 3, 21 , 22 are placed, said bodies including a longitudinal slot facing the distribution net 16.
  • an air-tight vacuum bag 13 is placed.
  • vacuum channels are provided in the form of perforated vacuum tubes 2.
  • the vacuum tubes 2 communicate with a vacuum source, and the inlet profile bodies 3, 21 , 22 communicate with a polymer source with liquid polymer.
  • the vacuum in the vacuum channels 2 generate a vacuum in the mould cavity between the solid mould part 1 and the vacuum bag 13, and thus polymer is drawn or sucked through the inlet profile bodies 3, 21 , 22 downwards into the distribution net 16 and along said distribution net 16 through the tear-off layer 15, as it spreads and impregnates the fibre insertion 14.
  • the inlet profile bodies 3 and the distribution net 16 are removed by means of the tear-off layer 15.
  • the inlet profile bodies 3, 21 , 22 and the vacuum channels 2 are not limited to the function described above, as during the process of filling the mould, one or more of said inlet profile bodies 3, 21 , 22 can communicate periodically with a vacuum source instead of with the polymer source, and the vacuum channels 2 can communicate with a polymer source instead of the vacuum source.
  • the process of filling the mould can start with only the middle one of the inlet profile bodies 22 communicating with the polymer source, as the remaining juxtaposed inlet profile bodies 21 , 3 and the vacuum channels 2 communicate with a vacuum source.
  • the inflowing polymer spreads from the middle inlet profile body 22 towards the closest two inlet profile bodies 21.
  • FIG. 2 shows a schematic view of the apparatus according to the invention.
  • the mould 1 has an outline corresponding to the outline of a blade shell half.
  • Each vacuum channel 2 and each inlet profile body 3, 21, 22 communicate via an inlet of the mould 4 with a valve member 5, which in turn communi- cates with both a polymer source 7 and a vacuum source 10.
  • Fig. 3 shows a schematic view of one of the valve members 5.
  • the valve member is a three-way valve member with two positions. In the position shown in Fig. 3, the inlet of the mould 4 communicates with the polymer source 7. If the valve member 5 is set into its second position, the inlet of the mould 4 is connected to the vacuum source 10.
  • the valve member 5 can also be shaped as a valve with for example three positions, in the middle position blocking the polymer source 7 as well as for the vacuum source 10. It goes without saying that other types of valve members can be applied as well, as it is essential that the inlet of the mould 4 can communicate with both a polymer source 7 and a vacuum source 10.
  • Figs. 4 and 5 show a cross-section through an inlet profile body 3 according to a particular embodiment.
  • the inlet profile body 3 is ⁇ - shaped as it includes a cylindrical wall and two flap parts 11, 12.
  • a slot 8, extending in the longitudinal direction of the profile body 3 between the two flap parts 11 , 12 connects the interior 6 of the profile body 3 with the mould cavity.
  • the slot 8 is covered by a semi-permeable membrane 9 extending from one flap part 11 to the second flap part 12.
  • the membrane 9 is semi- permeable in the sense that it admits air but not liquid polymer.
  • the membrane 9 is only secured to the profile body 3 at one end of the flap part 11 and thus it has the function of a flap valve or a flap check valve together with the profile body 3.
  • the negative pressure draws in the membrane 9, so that it abuts the second flap part 12 and blocks the passage of liquid polymer.
  • the negative pressure in the mould cavity draws the semi-permeable membrane 9 away from the second flap part 12, as shown in Fig. 5, whereby liquid polymer can flow from the interior of the profile body 3 and into the mould cavity.
  • the profile body 3 lifts up the vacuum bag 13 thus allowing liquid polymer to flow into the mould cavity via the slot resulting between the flap part 12 of the profile body and the membrane 9.
  • the inlet profile bodies 3, 21 , 22 are shaped like ⁇ -formed profile bodies, and the vacuum channels 2 are shaped like perforated tubes.
  • the inlet channels 3, 21 , 22 can, however, also be shaped like perforated tubes just as the vacuum channels 2 can be shaped like ⁇ -formed profile bodies. If perforated tubes are applied, these can optionally be reinforced by a helical pin member extending inside the tube and preventing the tube from folding up due to the vacuum.

Abstract

Apparatus and method of producing fibre composite mouldings by means of vacuum infusion applying a mould with a mould cavity, a plurality of inlet channels (3, 21, 22) communicating with the mould cavity and a polymer source (7) with liquid polymer, a plurality of vacuum channels (2) communicating with the mould cavity and a vacuum source (10), where fibre material (14) is inserted into the mould cavity prior to the process of filling said mould, and where a negative pressure is generated in the vacuum channels (2) and thus in the mould cavity with the result that liquid polymer is drawn from the polymer source (7) via the inlet channels (3, 21, 22) into the mould cavity. One or more of the inlet channels (3, 21, 22) can also communicate with a vacuum source, and/or one or more of the vacuum channels (2) can also communicate with a polymer source (7).

Description

Title: Method and apparatus for producing fibre composite mouldings by means of vacuum infusion.
Technical Field
The invention relates to a method according to the preamble of claim 1 and to an apparatus according to the preamble of claim 9.
Thus the invention relates to a method and an apparatus for producing fibre composite mouldings by means of VARTM (vacuum assisted resin transfer moulding), where liquid polymer, also called resin, is filled into a mould cavity, in which fibre material priorly has been inserted, where a vacuum is generated in the mould cavity hereby drawing in the polymer. Often a minor positive pressure is generated at the inlet side in order to improve the filling therein of polymer.
Vacuum infusion is a process used for moulding fibre composite mouldings, where uniformly distributed fibres, said fibres being rovings, i.e. bundles of fibre bands, bands of rovings or mats, which are either felt mats made of in- dividual fibres or woven mats made of fibre rovings, are layered in one of the mould parts. The second mould part is often made of resilient vacuum bag, and is subsequently placed on top of the fibre material. By generating a vacuum, typically 80 to 90% of the total vacuum, in the mould cavity between the inner side of the mould part and the vacuum bag, the liquid polymer can be drawn in and fill the mould cavity with the fibre material contained herein. So-called distribution layers or distribution tubes, also called inlet channels, are used between the vacuum bag and the fibre material in order to obtain as sound and efficient a distribution of polymer as possible. In most cases the polymer applied is polyester or epoxy, and the fibre reinforcement is most often based on glass fibres or carbon fibres.
During the process of filling the mould, a vacuum, said vacuum in this con- nection being understood as a negative pressure, is generated via the vacuum channels in the mould cavity, whereby liquid polymer is drawn into the mould cavity via the inlet channels in order to fill said mould cavity. From the inlet channels the polymer disperses in the mould cavity as a flow front moves towards the vacuum channels. Thus it is important to position the inlet channels and vacuum channels optimally in order to obtain a complete filling of the mould cavity. Ensuring a complete distribution of the polymer in the entire mould cavity is, however, often difficult, and accordingly this often results in so-called dry spots, i.e. areas with fibre material not being suffi- ciently impregnated with resin. Thus dry spots are areas where the fibre material is not impregnated, and where there can be air pockets, which are difficult or impossible to remove by controlling the vacuum pressure and possibly an overpressure at the inlet side. In connection with vacuum infusion, employing a solid mould part and a resilient mould part in the form of a vac- uum bag, the dry spots can be repaired after the process of filling the mould by for example puncturing the cloth in the respective location and by drawing out air for example by means of a syringe needle. Liquid polymer can optionally be injected in the respective location, and this can for example be done by means of a syringe needle as well. This is a time-consuming and tiresome process. In the case of large mould parts, staff have to stand on the vacuum bag, which is not desirable, especially not when the polymer has not hardened, as it can result in deformations in the inserted fibre material and thus in a local weakening of the structure, as well as result in an unintentional perforation of the vacuum bag.
Background Art
DE 199 22 850 discloses an apparatus for producing fibre composite mouldings. The apparatus includes a mould part, where the channels extend in the longitudinal direction of the apparatus below the moulding surface, and where the channels are connected to said surface through bores or longitudinal slots. A plurality of valve members communicating with a vacuum source and a resin source, respectively, is placed at each end of the channels. Every second channel communicates with the vacuum source, and every second channel communicates with the resin source, and by time varying the setting of the valve members the flow front of the resin can be controlled during the impregnation process.
Disclosure of Invention
The object of the invention is to provide a method and an apparatus avoiding these draw-backs. By means of the method according to the invention this object is achieved by periodically interrupting the connection of one or more of the inlet channels to the polymer source during the process of filling the mould, and by connecting said inlet channel or inlet channels to a vacuum source, so that liquid polymer in the mould cavity is drawn into the direction of said inlet channels, and/or by periodically interrupting the connection of one or more of the inlet channels to the vacuum source during the process of filling the mould, and by connecting said vacuum channel or channels to a polymer source, so that liquid polymer is drawn into the mould cavity through said vacuum channel or channels. Usually the vacuum channels and the inlet channels have one function only, as the vacuum channels draw air out of the mould cavity, and the inlet channels direct liquid polymer into the mould cavity. Periodically allowing the inlet channels or the vacuum channels to have the reverse function according to the invention results in much greater flexibility. If, for example, a dry spot has occurred adjacent an inlet channel, a vacuum can be generated in said inlet channel, thus drawing the polymer around the dry spot in the direction of the respective inlet channel and pressing the dry spot into the same direction thus impregnating the area. Due to a pressure drop which increases with the distance from the vacuum channel, it can be difficult to remove dry spots found at a large dis- tance from a vacuum channel. Leaks between the mould cavity and its surroundings, for example due to a punctured vacuum bag, also result in a pressure drop and thus increase the risk of dry spots. The option of drawing air out via the inlet channels instead of only drawing air out via the vacuum channel according to the invention provides an improved possibility of generating a powerful local vacuum.
According to an embodiment, the mould cavity is formed by a solid mould part and a resilient vacuum bag. The invention is particularly suitable for this type of mould as the use of a vacuum bag includes a particular risk of leaks.
According to an advantageous embodiment, the inlet channels and/or vac- uum channels are placed against the vacuum bag.
According to a preferred embodiment, the inlet channels and/or vacuum channels are shaped as oblong hollow profile bodies, the interior of which communicates with the interior of the mould cavity through one or more slots extending in the longitudinal direction of the profile body.
According to a particularly advantageous embodiment, the slot or the slots in one or more of the oblong hollow profile bodies are covered by a semipermeable membrane admitting air, but not admitting liquid polymer, and which are only partly fixed to the profile body. For example, the membrane can be fixed on one side of the slot but not on the other side of the slot. As a result, the profile body obtains the function of a "flap valve", as the profile body allows for the discharge of liquid polymer when applied as an inlet channel, because one side of said membrane is pressed away from the pro- file body, or because the profile body is pressed away from the membrane thus creating an opening between the membrane and one side of the profile body. When the profile body is used as a vacuum channel, the negative pressure in the interior of the profile body draws in the membrane so that it abuts said profile body, thus only admitting air into the interior of the profile body through the pores of the semi-permeable membrane. In this manner polymer is prevented from being drawn out of the mould cavity. According to one embodiment, the body produced is an oblong shell member, where the oblong profile bodies extend substantially parallel in the longitudinal direction of the shell member, the process of filling the mould starting with a plurality of the inlet channels communicating with the vacuum source. As a result a fast evacuation of air from the mould cavity takes place, where a flow front for the polymer drawn into the mould cavity moves towards the inlet profile bodies, and where the vacuum connection to the individual profile bodies is interrupted, when the flow front reaches said profile bodies as said profile bodies are subsequently connected to the polymer source. As a result, a particularly fast and efficient filling of the mould is achieved as a powerful vacuum is ensured adjacent the flow front at the same time as the feeding of polymer is ensured adjacent the flow front.
According to an embodiment, the process of filling the mould starts with one or more of the centrally placed inlet profile bodies communicating with the polymer source as the flow front moves from the polymer source in the direction of the longitudinal sides of the shell member. Thus a particularly fast and efficient filling of the mould is achieved.
According to one embodiment, the body is a blade shell half or a complete blade shell for a blade of a wind turbine.
The apparatus according to the invention includes a mould with a mould cavity, a polymer source for liquid polymer, a plurality of inlet channels, which are connected to the mould cavity and via valve members are connected to the polymer source, a vacuum source, a plurality of vacuum channels, which are connected to the mould cavity and via valve members are connected to the vacuum source, characterized in that one or more of the inlet channels by means of valve members also are connected to a vacuum source, and/or that one or more of the vacuum channels via valve members also are connected to the polymer source. Brief Description of the Drawings
The invention is explained in detail below with reference to an embodiment shown in the drawings, in which
Fig. 1 is a sectional view along line l-l in Fig. 2 through a mould for the production of a blade shell half,
Fig. 2 is a schematic view of an apparatus for carrying out the method according to the invention,
Fig. 3 shows a valve body included in the apparatus shown in Fig. 2,
Fig. 4 is a sectional view through an inlet profile body in a state, where it communicates with a vacuum source, and
Fig. 5 is a sectional view through the inlet profile body shown in Fig. 3 in a state, where it communicates with a polymer source.
Best Mode for Carrying out the Invention
Fig. 1 is a sectional view through a mould for the production of a blade shell half for a blade of a wind turbine by vacuum infusion and shows a solid mould part 1 with a top side mating to the exterior top side of the completed blade shell half. A fibre insertion 14 of for example glass fibre or carbon fibre is placed on the inner top side of the mould part 1. On top of the fibre insertion 14, a tear-off layer 15 is placed which can be a net or a perforated film, and on top of the tear-off layer 15 a distribution net or a flow layer 16 is placed. On top of the distribution net / flow layer 16 a plurality of Ω-shaped inlet pro- file bodies 3, 21 , 22 are placed, said bodies including a longitudinal slot facing the distribution net 16. On top hereof an air-tight vacuum bag 13 is placed. At the flanges of the mould, vacuum channels are provided in the form of perforated vacuum tubes 2. According to prior art, the vacuum tubes 2 communicate with a vacuum source, and the inlet profile bodies 3, 21 , 22 communicate with a polymer source with liquid polymer. The vacuum in the vacuum channels 2 generate a vacuum in the mould cavity between the solid mould part 1 and the vacuum bag 13, and thus polymer is drawn or sucked through the inlet profile bodies 3, 21 , 22 downwards into the distribution net 16 and along said distribution net 16 through the tear-off layer 15, as it spreads and impregnates the fibre insertion 14. Upon the completion of curing the vacuum bag 13, the inlet profile bodies 3 and the distribution net 16 are removed by means of the tear-off layer 15.
According to the invention the inlet profile bodies 3, 21 , 22 and the vacuum channels 2 are not limited to the function described above, as during the process of filling the mould, one or more of said inlet profile bodies 3, 21 , 22 can communicate periodically with a vacuum source instead of with the polymer source, and the vacuum channels 2 can communicate with a polymer source instead of the vacuum source. Thus the process of filling the mould can start with only the middle one of the inlet profile bodies 22 communicating with the polymer source, as the remaining juxtaposed inlet profile bodies 21 , 3 and the vacuum channels 2 communicate with a vacuum source. Thus the inflowing polymer spreads from the middle inlet profile body 22 towards the closest two inlet profile bodies 21. When the flow front reaches the latter, their connection to the vacuum source is disrupted, and they are connected to the polymer source. Subsequently, the flow front moves on towards the next inlet profile bodies 3 etc. Thus a pressure drop resulting from any possible unintentional perforation of the vacuum bag 13 and/or a strong air resistance either in the fibre insertion 14 pressed together due to the vacuum or in the distribution net does not prevent a powerful vacuum from applying adjacent the flow front. A possible dry spot can also be removed again by connecting one of the inlet profile bodies with the vacuum source thus reversing the flow direction of the polymer. Fig. 2 shows a schematic view of the apparatus according to the invention. The mould 1 has an outline corresponding to the outline of a blade shell half. Each vacuum channel 2 and each inlet profile body 3, 21, 22 communicate via an inlet of the mould 4 with a valve member 5, which in turn communi- cates with both a polymer source 7 and a vacuum source 10.
Fig. 3 shows a schematic view of one of the valve members 5. As it can be seen, the valve member is a three-way valve member with two positions. In the position shown in Fig. 3, the inlet of the mould 4 communicates with the polymer source 7. If the valve member 5 is set into its second position, the inlet of the mould 4 is connected to the vacuum source 10. Of course, the valve member 5 can also be shaped as a valve with for example three positions, in the middle position blocking the polymer source 7 as well as for the vacuum source 10. It goes without saying that other types of valve members can be applied as well, as it is essential that the inlet of the mould 4 can communicate with both a polymer source 7 and a vacuum source 10.
Figs. 4 and 5 show a cross-section through an inlet profile body 3 according to a particular embodiment. In the cross-section the inlet profile body 3 is Ω- shaped as it includes a cylindrical wall and two flap parts 11, 12. A slot 8, extending in the longitudinal direction of the profile body 3 between the two flap parts 11 , 12 connects the interior 6 of the profile body 3 with the mould cavity. The slot 8 is covered by a semi-permeable membrane 9 extending from one flap part 11 to the second flap part 12. The membrane 9 is semi- permeable in the sense that it admits air but not liquid polymer. The membrane 9 is only secured to the profile body 3 at one end of the flap part 11 and thus it has the function of a flap valve or a flap check valve together with the profile body 3. When the inlet profile body 3 communicates with the vacuum source 10, the negative pressure draws in the membrane 9, so that it abuts the second flap part 12 and blocks the passage of liquid polymer. When the inlet profile body 3 communicates with the polymer source 7, the negative pressure in the mould cavity draws the semi-permeable membrane 9 away from the second flap part 12, as shown in Fig. 5, whereby liquid polymer can flow from the interior of the profile body 3 and into the mould cavity. If the membrane 9 cannot be moved inwards towards said mould cav- ity due to the fibre material in the mould cavity, and if a slight positive pressure is generated in the interior 6 of the inlet profile body, the profile body 3 lifts up the vacuum bag 13 thus allowing liquid polymer to flow into the mould cavity via the slot resulting between the flap part 12 of the profile body and the membrane 9.
In the embodiment shown in Fig. 1 the inlet profile bodies 3, 21 , 22 are shaped like Ω-formed profile bodies, and the vacuum channels 2 are shaped like perforated tubes. The inlet channels 3, 21 , 22 can, however, also be shaped like perforated tubes just as the vacuum channels 2 can be shaped like Ω-formed profile bodies. If perforated tubes are applied, these can optionally be reinforced by a helical pin member extending inside the tube and preventing the tube from folding up due to the vacuum.
List of reference numerals
1 Solid mould part
2 Vacuum channels 3 Inlet channels
4 Inlet of the mould
5 Valve members
6 Interior of the inlet channels
7 Polymer source with liquid polymer 8 Slots
9 Semi-permeable membrane
10 Vacuum source
11 First flap of the inlet profile body
12 Second flap of the inlet profile body 13 Vacuum bag
14 Fibre insertion
15 Tear-off layer
16 Distribution net 21 Inlet channel 22 Inlet channel

Claims

Claims
1. Method of producing fibre composite mouldings by means of vacuum infusion applying a mould with a mould cavity, a plurality of inlet channels (3, 21 , 22) communicating with the mould cavity and a polymer source (7) with liquid polymer, a plurality of vacuum channels (2) communicating with the mould cavity and a vacuum source (10), where fibre material (14) is inserted into the mould cavity prior to the process of filling said mould, and where a negative pressure is generated in the vacuum channels (2) and thus in the mould cavity during the process of filling the mould with the result that liquid polymer is drawn from the polymer source (7) via the inlet channels (3, 21 , 22) into the mould cavity characterized in that the connection of one or more of the inlet channels (3, 21 , 22) to the polymer source (7) is interrupted periodically during the process of filling the mould, and that said inlet channel or channels (3, 21 , 22) are connected to a vacuum source (10) so that liquid polymer in the mould cavity is drawn into the direction of said inlet channels (3, 21 , 22), and/or that the connection of one or more of the inlet channels (2) to the vacuum source (10) is interrupted periodically during the process of filling the mould, and that said vacuum channel or channels are connected to a polymer source (7) so that liquid polymer is drawn into the mould cavity through said vacuum channel or channels (2).
2. Method according to claim 1 characterized in that the blank produced is an oblong shell member, where the inlet channels (3, 21 , 22) and the vac- uum channels (2) are oblong and extend substantially parallel to the longitudinal direction of the shell member, where the process of filling the mould starts with one or more centrally placed inlet channels (3, 21 , 22) being connected to the polymer source (7), and with one ore more juxtaposed inlet channels (3, 21 , 22) being connected to the vacuum source (10), a flow front of the polymer drawn into the mould cavity moving from the centrally placed inlet channel(s) (3, 21 , 22) towards the juxtaposed inlet channels (3, 21 , 22), where the vacuum connection to the juxtaposed inlet channels (3, 21 , 22) is interrupted, when the flow front reaches these channels as said inlet channels are subsequently connected to the polymer source (7).
3. Method according to claim 2 characterized in that the flow front con- tinues towards additional juxtaposed inlet channels (3, 21 , 22) which are also connected to the vacuum source (10) at the beginning of the process of filling the mould, where the vacuum connection to these inlet channels is interrupted when the flow front reaches these inlet channels as they are subsequently connected to the polymer source (7).
4. Method according to one of the preceding claims, where the mould cavity is defined by a solid mould part (1 ) and a resilient vacuum bag (13).
5. Method according to claim 4, where the inlet channels (3, 21 , 22) and/or the vacuum tubes (2) are placed against the vacuum bag (13).
6. Method according to one of the preceding claims, where the inlet channels (3, 21 , 22) and/or the vacuum tubes (2) are shaped as oblong hollow profile bodies, the interior (6) of which communicates with the interior of the mould cavity through one or more slots (8) extending in the longitudinal direction of the profile body.
7. Method according to claim 6, where the slot or the slots (8) in one or more of the oblong hollow profile bodies are covered by a semi-permeable membrane (9) admitting air, but not admitting liquid polymer, and which are only partially fixed to the profile body.
8. Method according to claim 6 or 7, where the body produced is an oblong shell member, and where the oblong profile bodies extend substantially parallel in the longitudinal direction of the shell member, the process of filling the mould starting with a plurality of the centrally placed juxtaposed inlet channels (3, 21 , 22) communicating with the vacuum source (10) resulting in a fast evacuation of air from the mould cavity, where a flow front for the polymer drawn into the mould cavity moves from the centrally placed inlet channels in the direction of the longitudinal sides of the shell member, and where the vacuum connection to the individual profile bodies (3, 21 , 22) is interrupted when the flow front reaches said profile bodies as said profile bodies are subsequently connected to the polymer source (7).
9. Method according to claim 8, where the body produced is a blade shell half for a blade of a wind turbine.
10. Apparatus for producing oblong fibre composite mouldings by way of vacuum infusion, said apparatus including a mould with a mould cavity, a polymer source (7) for liquid polymer, a plurality of inlet channels (3, 21 , 22) which are connected to the mould cavity and which via valve members (5) are connected to a polymer source (7), a vacuum source (10), a plurality of vacuum channels (2), which are connected to the mould cavity and via valve members (5) are connected to the vacuum source (10), where the inlet channels (3, 21 , 22) and the vacuum channels (2) are substantially parallel to each other in the longitudinal direction of the mould, and where one or more of the inlet channels (3, 21 , 22) via valve members (5) are also connected to a vacuum source (10), and where one or more of the vacuum channels (2) via valve members (5) are also connected to a polymer source (7) characterized in that the vacuum source (10) and the polymer source (7) via the valve members (5) are connected to the same end of the inlet channels (3, 21 , 22) and the vacuum channels (2).
11. Apparatus according to claim 10 characterized in that at least one of the valve members (5) is made to change between a position in which it connects a channel to the vacuum source (10) and disrupts the connection to the polymer source (7) and a position in which it connects said channel to the polymer source (7) and disrupts the connection to the vacuum source (10).
PCT/DK2005/000766 2004-11-30 2005-11-30 Method and apparatus for producing fibre composite mouldings by means of vacuum infusion WO2006058541A1 (en)

Priority Applications (11)

Application Number Priority Date Filing Date Title
MX2007006325A MX2007006325A (en) 2004-11-30 2005-11-30 Method and apparatus for producing fibre composite mouldings by means of vacuum infusion.
EP05809241.2A EP1819502B1 (en) 2004-11-30 2005-11-30 Method and apparatus for producing fibre composite mouldings by means of vacuum infusion
AU2005312178A AU2005312178B2 (en) 2004-11-30 2005-11-30 Method and apparatus for producing fibre composite mouldings by means of vacuum infusion
DK05809241.2T DK1819502T3 (en) 2004-11-30 2005-11-30 Method and apparatus for preparing fiber composite blanks by vacuum infusion
US11/791,710 US7939001B2 (en) 2004-11-30 2005-11-30 Method and apparatus for producing fibre composite mouldings by means of vacuum infusion
BRPI0518697A BRPI0518697B1 (en) 2004-11-30 2005-11-30 method and apparatus for producing fiber composite moldings by vacuum infusion
CN200580047437XA CN101124079B (en) 2004-11-30 2005-11-30 Method and apparatus for producing fibre composite mouldings by means of vacuum infusion
JP2007543708A JP4921380B2 (en) 2004-11-30 2005-11-30 Method and apparatus for manufacturing fiber composite molded article by vacuum injection method
CA2588849A CA2588849C (en) 2004-11-30 2005-11-30 Method and apparatus for producing fibre composite mouldings by means of vacuum infusion
NO20073381A NO339058B1 (en) 2004-11-30 2007-06-29 Method and apparatus for making fiber composite molds by means of vacuum infusion
AU2010236084A AU2010236084B2 (en) 2004-11-30 2010-10-28 Method and apparatus for producing fibre composite mouldings by means of vacuum infusion

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DKPA200401865 2004-11-30
DK200401865A DK176150B1 (en) 2004-11-30 2004-11-30 Method and apparatus for preparing fiber composite blanks by vacuum infusion

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BR (1) BRPI0518697B1 (en)
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JP2008521649A (en) 2008-06-26
AU2010236084A1 (en) 2010-11-18
MX2007006325A (en) 2007-10-23
CN101124079A (en) 2008-02-13
DK1819502T3 (en) 2014-01-20
EP1819502A1 (en) 2007-08-22
US7939001B2 (en) 2011-05-10
JP4921380B2 (en) 2012-04-25
CN101124079B (en) 2010-06-23
DK176150B1 (en) 2006-10-16
BRPI0518697A2 (en) 2008-12-02
AU2010236084B2 (en) 2012-06-14
NO339058B1 (en) 2016-11-07
DK200401865A (en) 2006-05-31
US20090115112A1 (en) 2009-05-07
BRPI0518697B1 (en) 2015-12-08
NO20073381L (en) 2007-08-29
AU2005312178A1 (en) 2006-06-08
EP1819502B1 (en) 2013-10-09
CA2588849A1 (en) 2006-06-08
AU2005312178B2 (en) 2010-11-18

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