JEC COMPOSITES MAGAZINE - Issue #119 - Supplement lnnovation report - 50

JEC WORLD 2018
R&D
Innovative wind turbine blade design
> Booth:
Developing a large-scale blade is a major challenge in today's competitive Hall 6 - N4
wind turbine market simply because a wind turbine with large-scale blades
is the most effective way to bring down the cost of energy (CoE). Rotor blades up to 70
m long with power ratings up to 2.5-7 MW are already available in the market, and their
size is expected to grow more in the near future. In a conventional blade design, identical layups and materials have traditionally been used for the pressure and suction (front
or back) sides of the blades. However, this
often causes more stresses in the blades,
involving more material usage. To reduce
material consumption and achieve larger
blades, the blade design needs to be innovative and optimized.
Hanyang University researchers (Korea) developed a non-symmetrical skin and spar cap design for the pressure side (PS) and suction side (SS) of the blades. This new design proved to be
very cost-effective and efficient. According to the current studies, shallow fibre angles (e.g. 30
degrees for the PS and 45 degrees for the SS) are stronger than 45 degrees for both sides since a
30-degree laminate offers more tensile resistance whereas a 45-degree one has greater buckling
resistance. Similarly, glass fibre was found to be more cost effective for the spar cap of the SS
due to the high failure strains of glass fibres, and carbon fibre is better for spar cap of the PS. The
new blade design can save 10 to 30% of materials and cost compared to conventional design.

Wind energy

Multi-sector

Pultrusion of graphene- > Booth:
graphite composites
Hall 5 - C77
Graphenano Composites produces pultruded
composite parts using nanomaterials based on
graphene-graphite geometries incorporated
in the matrix. The graphene-based geometries
are produced using a
CVD (Chemical Vapour
Deposition) modified synthesis process for integration in polymer matrices
such as epoxy, polyester
or PU. The manufacturing
process includes the purification, sieving and functionalization of nanocomponents and their chemical incorporation in polymeric materials. The masterbatch
is produced using mechanical mixture and ultrasonic
dispersion procedures. It is chemically formulated for
integration in a reactor and/or an industrial manufacturing solvent. Furthermore, the company developed
new in-house test protocols to measure the enhanced
mechanical properties of composite additives including graphene nanomaterials, as well as the UMH
(Universidad Miguel Hernandez) non-destructive
test protocol using ultrasound technology.

www.hanyang.ac.kr

Marine

Multi-sector

Structural winding of FRP components
> Booth:
The innovative structural winding process developed by SGL Group Hall 6 - D25
combines all the attributes required by future-oriented manufacturing processes for fiNew manufacturing
> Booth:
bre-reinforced plastics. The load-path optimized topology based on an anisotropic maprocess for tidal blades
Hall 6 - R72
terial results in an ultra-light structural design.
IRT Jules Verne and eight SMEs joined their
A structured approach is essential for the comprehensive engineering of an ultralight
skills to develop a new low-cost, high-volume component. For this simulation-driven approach, a load spectrum is required that can be
manufacturing process for tidal blades. This identified by multi-axial dynamic measurement. These specifications are transferred into
project was technically supported by a key player in
ideas or sketches. These concepts, together with
the sector. The project involved many innovations in
the prevailing load spectrum, are converted into a
terms of design, numerical modelling tools, process
working design. Before the final design is defined,
(manufacturing and tooling) and coating. Two techa feasibility study with the correct manufacturing
nologies were compared: prepreg and RTM, using
technology is needed to be able to design the tool.
vinylester resin and carbon and glass fibres. Each step
Afterwards, prototypes are wound to approve the
(design, materials, tooling, manufacturing process,
design, and these components are tested to valiand coating) was optimized in order to define the
date the simulation results.
most competitive manufacturing process.
The objective of a more competitive solution than cur- To get the full potential of this innovative process, a high-quality material is needed. The main
rent solutions on the market was reached. Moreover, advantage of this type of material is the decoupling of the impregnation from the component
a comparative technical and economic study of the manufacturing process. This leads to a constant fibre volume content and constant width
two technologies (RTM and prepreg) demonstrated of the tow, enabling an automated process with higher laying speed. Moreover, the process
the advantages of RTM technology for such parts. The is cleaner and the curing process is easier compared to the classical wet-winding approach.
blueprint of an automated production unit (target: As a typical application for the sports sector, bike components that benefit from ultra-light
1000 units/year) was prepared. So, the dynamic col- design were produced. A 7g light bottle holder was designed based on the defined load cases
laboration of the partners led to very satisfying results, and a stress optimization study. A chain ring, weighing 34g, was tested in several races and
which could be industrialised very rapidly. The part- already lasted 4000 km. A handlebar stem and a seat clamp are the latest components develners are confident that this result will rapidly generate oped, showing the full potential of this development approach: with fibres only oriented in
business opportunities.
the loading direction, the minimum physical weight was achieved.
www.graphenanocomposites.com

www.irt-jules-verne.fr

jec composites magazine / N° 119 supplement - Innovation Report

www.sglgroup.com

http://www.hanyang.ac.kr http://www.graphenanocomposites.com http://www.irt-jules-verne.fr http://www.sglgroup.com

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #119 - Supplement lnnovation report