Infused spar cap using a low viscosity matrix material

Abstract

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.

What is claimed is: 
     
         1 . A wind turbine blade spar cap prepared by a method comprising:
 preparing a high density fabric with a low viscosity resin system to provide a composite material,   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 wind turbine blade spar cap of  claim 1 , wherein the spar cap is characterized by a composite modulus of greater than about 48000 MPa. 
     
     
         3 . The wind turbine blade spar cap of  claim 1 , wherein the composite material is characterized by a fiber volume fraction of greater than about 65%. 
     
     
         4 . The wind turbine blade spar cap of  claim 1 , wherein the low viscosity resin system comprises a monomer and the method further comprises curing the composite material to polymerize the low viscosity resin system. 
     
     
         5 . The wind turbine blade spar cap of  claim 4 , wherein the method further comprises post-curing of the composite material to cross-link the polymerized low viscosity resin system. 
     
     
         6 . The wind turbine blade spar cap of  claim 1 , wherein the low viscosity resin system comprises a dicyclopentadiene resin, a poly(butylene terephthalate) cyclized resin, a polycaprolactone resin, a polyester or vinylester having a high styrene content, or a combination thereof. 
     
     
         7 . The wind turbine blade spar cap of  claim 1 , wherein the high density fabric comprises glass fibers, carbon fibers, or a combination thereof. 
     
     
         8 . The wind turbine blade spar cap of  claim 1 , wherein the step of preparing comprises laminating the high density fabric to the low viscosity resin system to form the composite material and curing the composite material. 
     
     
         9 . A wind turbine blade comprising the spar cap of  claim 1 . 
     
     
         10 . A wind turbine blade spar cap comprising a composite material prepared by applying a low viscosity resin system to a high density fabric to provide a composite material, 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. 
     
     
         11 . The wind turbine blade spar cap of  claim 10 , wherein the low viscosity resin system comprises a dicyclopentadiene resin, a poly(butylene terephthalate) cyclized resin, a polycaprolactone resin, a polyester or vinylester having a high styrene content, or a combination thereof. 
     
     
         12 . The wind turbine blade spar cap of  claim 10 , wherein the high density fabric comprises glass fibers, carbon fibers, or a combination thereof. 
     
     
         13 . The wind turbine blade spar cap of  claim 10 , wherein the spar cap is characterized by a composite modulus of greater than about 45000 MPa. 
     
     
         14 . The wind turbine blade spar cap of  claim 10 , wherein the spar cap is characterized by a composite modulus of greater than about 48000 MPa. 
     
     
         15 . The wind turbine blade spar cap of  claim 10 , wherein the composite material is characterized by a fiber volume fraction of greater than about 60%. 
     
     
         16 . The wind turbine blade spar cap of  claim 10 , wherein the composite material is characterized by a fiber volume fraction of greater than about 65%. 
     
     
         17 . The wind turbine blade spar cap of  claim 10 , wherein the spar cap is characterized by an increase in composite modulus in the range from about 10% to about 12% as compared to a spar cap prepared using an epoxy resin. 
     
     
         18 . The wind turbine blade spar cap of  claim 10 , wherein the composite material is characterized by an increase in fiber volume fraction in the range from about 14% to about 16% as compared to a spar cap prepared using an epoxy resin. 
     
     
         19 . The wind turbine blade spar cap of  claim 10 , wherein the composite material is characterized by an increase in fiber volume fraction of 15% as compared to a spar cap prepared using an epoxy resin. 
     
     
         20 . A wind turbine blade comprising the spar cap of  claim 10 .