Method for manufacture of an infused spar cap using a low viscosity matrix material
Embodiments of the present application generally provide for wind turbine blade spar caps comprising composite materials prepared using a low viscosity resin system and a high density fabric and methods for their manufacture. In particular embodiment, the low viscosity resin system has a viscosity in the range of about 1 to about 100 centipoises at a temperature in the range of about 0° C. to about 125° C. during the preparation of the composite material. By using low viscosity resin systems, composite materials have been prepared having a fiber volume fraction of greater than about 65% and a composite modulus of greater than 48000 MPa.
1. A method of manufacturing a wind turbine blade spar cap using a low viscosity resin system, comprising:
laminating a high density fabric with a low viscosity resin system to provide a composite material; and
curing the composite material,
wherein the composite material has a fiber volume fraction of greater than about 65%, and
wherein the low viscosity resin system has a viscosity in the range of about 1 to about 100 centipoises at a temperature in the range of about 0° C. to about 125° C.
2. The method of claim 1 , wherein the low viscosity resin system is selected from the group consisting of dicyclopentadiene resin, a poly(butylene terephthalate) cyclized resin, a polycaprolactone resin, a polyester having a high styrene content, a vinylester having a high styrene content, and combinations thereof.
3. The method of claim 1 , wherein the high density fabric comprises glass fibers, carbon fibers, or a combination thereof.
4. The method of claim 1 , wherein the low viscosity resin system comprises a monomer and the step of curing the composite material polymerizes the low viscosity resin system.
5. The method of claim 4 , further comprising a post-curing of the composite material to cross-link the polymerized low viscosity resin system.