Lightweight Wind Turbine Construction

Recovering carbon fiber and glass fiber from composite materials like wind turbine blades and waste composites like automotive parts. The process involves pyrolysis to decompose the materials at high temperatures, followed by separation to isolate the carbon fiber and glass fiber. The pyrolysis is done in stages, with a first pyrolysis at lower temperatures to extract oil, and a second pyrolysis at higher temperatures to fully decompose the materials. This allows recovering both carbon fiber and glass fiber in a single process. The pyrolysis gas is reformed and the oil is separated. The recovered fibers are then carded and pelletized.

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Polymeric composite materials with improved insulation properties while maintaining textural properties. The composite contains a continuous polymer matrix with dispersed aerogel particles. The aerogel particles are organic polymer-based aerogels like polyimide aerogels. Adding the aerogel particles to the composite delays the peak exotherm during curing, increases the deflection temperature, and lowers the composite's thermal conductivity and dielectric constant compared to the unfilled composite. The composite can have applications in insulation for electronics, pipes, buildings, etc.

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Manufacturing wind turbine blades with improved fiber-resin ratio and fatigue strength, especially for pre-bent blades. The method involves dividing the fiber layup into segments in areas prone to high fiber-resin ratio variation. It also uses flow barriers, like resin-impregnated strips or dissolvable substances, to prevent longitudinal resin flow past the barriers. This helps balance fiber and resin ratios in the layup segments. By segmenting and controlling resin flow, it prevents overly high fiber concentrations on the lower mould areas. This improves fatigue strength, particularly on the load-bearing upwind half of pre-bent blades.

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Wind turbine blade design with integrated lightning protection that reduces cost and complexity compared to conventional systems. The blade has carbon internal beams with carbon spar caps. Instead of full-length down conductors, there are partial ones at the tip and root. Carbon plates in the mid-region act as down conductors. This allows lightning to flow through the spar caps without needing a full-length conductor. The tip and root down conductors connect to select plate ends. The blade has a tip lightning receptor and root terminal. The tip and root down conductors connect there. This avoids full-length down conductors while still protecting the blade.

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Method to manufacture thick preform building elements for wind turbine blades that avoids issues like binder diffusion during curing. The method involves laying out fiber mats in sections with overlapping edges on a mold. A separate component is placed on the mold first. As each fiber mat is laid, the edge contacts the subcomponent. Binder is applied to the edge beforehand. Pressure is applied to the edge to secure the mat. This prevents binder diffusion into the core of thick preforms. The components are then cured.

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Polymethyl methacrylate (PMMA) rigid foam for use in wind power blade cores and boat sandwich composites that addresses the limitations of traditional foams like PET and PVC. The PMMA foam has lower resin absorption, higher glass transition temperature, and allows higher curing temperatures compared to PET/PVC foams. The PMMA foam properties enable better outer layer adhesion, lower total component weight, and faster curing times. The foam is made by foaming a PMMA composition with silicon oxide particles to achieve fine cell structure. The PMMA foam has an average pore size of 50-300 μm.

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High-performance glass composition for making stronger and lighter glass fibers for composites like wind blades. The composition has specific weight percentages of SiO2, Al2O3, CaO, MgO, Na2O, Li2O, and TiO2. It allows forming the fibers at lower temperatures, reducing bushing sag, while retaining favorable properties like high tensile strength and modulus. The composition is essentially lithium-free to enable lower fiberizing temps.

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Automated manufacturing method for wind turbine towers using additive printing to build the tower layer by layer, with integrated reinforcement. The method involves using a movable frame assembly with platforms that are raised vertically. As the platforms move, reinforcement bars are dispensed automatically from a separate assembly under tension. Then, cementitious material is printed onto the platforms to embed the bars. This allows continuous reinforcement as the tower grows. The printed layers are repeated to build the tower. The additive printing assembly has multiple printer heads for outer/inner walls and filler material.

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A wind turbine blade with a shear web that has improved strength-to-weight properties and load distribution compared to traditional blade designs. The shear web uses an open lattice structure made by 3D printing instead of solid materials. This allows customization based on load conditions and reduces weight. The lattice structure connects the flanges of the shear web to the blade spar caps. It provides better load distribution since the lattice spindles intersect at nodes instead of just at the flange edges. This reduces peak stresses and allows a more detailed design for specific loads. The 3D printing method also enables nested connection of blade sections for assembly.

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Abstract This study explores the development and optimization of polymer composite-based wind turbine blades, integrating glass fiber reinforced plastic (GFRP) with shape memory alloy (SMA) to enhance performance in energy harvesting. Advances materials science, aerodynamics, computational modelling, structural analysis have been leveraged improve blade efficiency, durability, self-adaptive capabilities. The research employs finite element (FEA) artificial neural networks (ANN) evaluate mechanical behaviour composite blades under varying loads. A graded beam model was developed assess effects ply drop-off material distribution on integrity. Experimental validation confirmed that SMA integration enhances deformation recovery, mitigating stress accumulation improving aerodynamic stability. results demonstrate GFRP-SMA achieve a coefficient approaching Betz limit (0.5923), reducing deflections load response. Despite these advancements, challenges remain optimizing wire placement, adhesion, actuation efficiency. Future work should focus refining interfaces, developing adaptive control me... Read More

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To bridge the mechanical performance gap between polyethylene terephthalate (PET) foam cores and balsa wood in wind turbine blades, this study proposes a hierarchical groove-perforation design for structural optimization. A finite element model integrating PET epoxy resin was developed validated against experimental shear modulus data ( < 0.5%). Machine learning combined with multi-island genetic algorithm (MIGA) optimized groove parameters (spacing: 7.5-30 mm, width: 0.9-2 depth: 0-23.5 perforation angle: 45-90) under constant infusion. The optimal configuration (width: 1 spacing: 15 65) increased by 9.2% (from 125 MPa to 137.1 MPa) enhanced compressive/tensile 10.7% compared conventional designs, without increasing core mass. Stress distribution analysis demonstrated that secondary grooves improved infiltration uniformity interfacial stress transfer, reducing localized strain concentration. Further integration of machine MIGA parameter optimization enabled reach 150 while minimizing weight gain, achieving balance material efficiency. This strategy offers cost-effective lightw... Read More

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Wind turbine component design for towers and blades that allows prefabrication, easier transportation, and faster assembly compared to traditional towers. The component has a wall element with a corrugated structural element attached to it. The corrugated shape reduces weight and allows compression during transportation. The component segments can be prefabricated and connected together at the tower or blade site. This allows preassembly of larger sections offsite, simplifies transportation, and speeds up installation compared to traditional tower assembly. The corrugated shape also provides strength and stiffness.

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Fiber reinforcement fabric for wind turbine components like blades and spar caps that allows easier and more efficient impregnation of resin during manufacturing. The fabric has tapered edges where the thickness gradually reduces towards the edge. This eliminates dry spots and air pockets by providing a smooth transition of resin fill as the fabric conforms to the tapered mold shapes. The fabric also enables easier layup of tapered fiber layers for components like spar caps by stitching together layers with terminated edges instead of manually arranging terminated plies.

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Floating wind turbine foundation design that reduces manufacturing cost while meeting anti-typhoon requirements. The floating foundation has a main body with an enclosed compartment. During normal conditions, the compartment is filled with water. During typhoons, the water level in the compartment is lowered to provide extra buoyancy to counteract the increased wind loads on the turbine. This allows using a lighter, less expensive foundation compared to traditional hardened foundations for anti-typhoon resistance.

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A system and method for recycling wind turbine blades into usable materials. The system involves scalping, shattering, breaking, screening, and grinding the shredded blade pieces to produce progressively finer fibers and strands. This allows recycling the fiberglass composite into reinforcement fibers and micro-fibers that can be used in new composites. The process stages include scalping off balsa wood, shattering the chips, breaking the fiber clusters, screening the strands, and grinding to micro-fiber size.

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Additive manufacturing (3D printing) technique for reinforcing large-scale structures like wind turbine towers using coiled polymer reinforcement members instead of conventional steel rings. The method involves printing the tower structure layers, unwinding continuous rolls of pultruded polymer reinforcement material into coils, placing the coils on the printed layers, and then printing more layers on top. This allows reinforcing the structure with lightweight, corrosion-resistant polymer instead of heavy steel rings. The coiled polymer members are wound and secured using fixtures to maintain shape during printing.

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Wind turbine blade made from environmentally-friendly material obtained from date palm trees. The blades are manufactured using natural material from date palm trees as an alternative to traditional blade materials. This reduces waste and environmental impact compared to conventional blades that are non-recyclable at the end of their life. The method involves extracting the date palm material and processing it into the blade structure.

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3D printed mold tool for making composite ducts that avoids the hazards and disadvantages of traditional eutectic salt methods. The tool has a sparse infill structure that allows fluid to flow through it. The tool is made of multiple 3D printed parts that assemble into a mold. Fluid is introduced into the sparse infill areas. This fluid permeates through the mold to partially cure a sacrificial fill material. The cured sacrificial mold is then used as a mandrel to shape the composite ducts. The 3D printed mold tool eliminates the need for destructive removal of salt molds and provides a lighter, faster, and safer alternative.

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Carbon fiber-reinforced polyetheretherketone (CF/PEEK) composite offer lightweight, high strength and toughness by combining benefits of resin fiber materials. However, current shaping methods face challenges such as forming difficulties, inconsistent shapes, significant mechanical damage. Herein, a CF/PEEK thermoforming device were designed. Thermoforming employs two heating molds (crimping mold at 310C roll pipe 400C) coiling roller operating 45 rpm to enable automatic efficient continuous production pipes with diameters ranging from 3 5 mm. High-strength retain excellent thermal stability during shaping, commendable properties-tensile 1467 N (decrease 8.8 %) specific stiffness 1.61 10 6 Nm/kg, 35-fold increase. Furthermore, stronger braided winding points introduced into hollow truss enhance their strengths, radial compression node-reinforced structure is 550 (improved 151 % compared that single pipe). This truss, its ultra-lightweight tensile/compressive strength, significantly expands application potential

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Lightweight, high-strength covered foam for applications like wind turbine blades, boats, cars, and buildings that use a renewable and sustainable material for the foam core. The foam is made from a copolymer containing ethylene furanoate and ethylene terephthalate units. It uses blowing agents like HFO-1234ze(E) to expand the polymer into a foam. The foam is covered with a separate material to provide strength and protection. This allows using a lighter foam for weight savings while maintaining strength in critical areas. The foam can be extruded into shapes like wind turbine blade cores, boat hulls, car underbody panels, or building insulation.

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Lightweight, high-strength closed-cell foam made from renewable and sustainable materials like polyethylene furanoate (PEF) that can be used in applications like wind turbine blades, sports equipment, transportation, and construction. The foam is extruded from a composition containing PEF polymers, tannins, and a select group of blowing agents. The foam has low density and good mechanical properties like strength and stiffness. The PEF cells contain a mixture of ethylene furanoate and ethylene terephthalate moieties. The foam can be face-sheeted with other materials for applications like wind turbine blades, or used as a standalone foam article.

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Lightweight, high-strength covered foam used in applications like transportation devices, building structures, and wind turbine blades. The foam has closed cell structure made from a polyethylene furanoate copolymer containing furanoate moieties. The foam is covered with a facing material like glass fiber reinforced polymer. The furanoate polymer provides strength and low density, while the covering provides additional strength. The blowing agent used is hydrofluoroolefin (HFO).

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This review investigates interlayer hybrid fiber composites for wind turbine blades (WTBs), focusing on their potential to enhance blade damage tolerance and maintain structural integrity. The objectives of this are: (I) assess the effect different lay-up configurations failure analysis (II) identify combinations WTBs supplement or replace existing glass fibers. Our method involves comprehensive qualitative quantitative analyses literature. Qualitatively, we tolerance-with an emphasis impact load-and under operational load six distinct configurations. Quantitatively, compare tensile flexural properties-essential integrity-of composites. reveals that placing high elongation (HE)-low stiffness (LS) fibers, e.g., glass, impacted side reduces size improves residual properties Placing low (LE)-high (HS) carbon, in middle layers, protects them during equips with mechanisms delay various conditions. A sandwich HE-LS fibers outermost LE-HS innermost layers provides best balance between integrity post-impact properties. benefits from synergistic effects, including bridging, enhanced buckling ... Read More

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ABSTRACT Carbon fiberreinforced polymer composites (CFRPs) are extensively employed in engineering applications owing to their exceptional strengthtoweight ratio and outstanding fatigue resistance. Nevertheless, when utilized critical components such as aircraft wings, wind turbine blades, structural elements, performance durability frequently degraded by harsh environmental conditions. To address these challenges, thermoplastic polyurethane (TPU) nonwoven fabric was introduced an interlayer carbon fiber/epoxy (CF/EP) improve both erosion resistance interlaminar fracture toughness. Experimental investigations revealed remarkable enhancements mechanical properties: the CF/TPU/EP exhibited a 28.6% increase maximum load, 11.8% improvement tensile strength, substantial 45.3% augmentation bending load compared conventional CF/EP composites. Moreover, demonstrated progressive enhancement with increasing impact angles (30 90), showing improvements of 58%, 130%, 185%, 227%, 292%, respectively. These results clearly demonstrate that TPUmodified achieve superior toughness while... Read More

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Carbon fiber-reinforced composite (CFRP) material with improved lightning strike resistance without adding conductive particles. The CFRP has a structure that reduces the risk of edge glow during lightning strikes. The key feature is a specific layer with carbon fibers closely packed together to form conductive paths between layers. The layer has a unique fiber orientation distribution with low void content in the fiber direction. This forces the fibers to contact each other and provides direct conduction between layers. The CFRP also has high overall conductivity in the thickness direction.

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A panel with alternating connected and unconnected regions between skins and an intermediate portion. The panel provides reduced weight with improved strength compared to solid intermediate sections. The connected regions have protrusions in one skin and recesses in the other, alternating with unconnected regions. The sizes in the connected regions gradually change perpendicular to the direction of alternation. This allows localized connection and prevents concentration of forces. It also allows controlled cooling without sudden temperature drops.

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Additively manufactured aerospace panels with integrated truss structures to eliminate joints and reduce weight. The panels have a single monolithic structure formed by printing the skins and truss members together. The skins have lattice regions to eliminate support during printing. The truss members connect the skins and extend between intersections of the lattice grids. This allows complex shapes and features like closeout walls to be printed in one step. The panels have optimized truss angles and truss density variations for strength and thermal management.

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A near-net shape manufacturing process called in-situ friction stir forging (I-FSF) that can form complex shapes from lightweight materials like aluminum and magnesium without preheating. The process involves using a rotational tool to friction stir the material at lower temperatures than conventional forging. This intense plastic deformation and local heating enables near-net shape forming of complex parts like gears. The friction stirring also refines grain size, develops non-conventional textures, and distributes reinforcements. A simulation and microstructure analysis confirmed the process.

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Joining unidirectional composite tapes without creating thickness variations that can cause kinking and buckling. The method involves abutting the ends of the tapes together without overlapping (butt joint) instead of overlapping and fusing. Then a prepreg with short fibers in the running direction is placed over the butt joint and fused. This creates a solid joint without thickness differences like overlapping would.

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Helicoidal composite materials with improved impact resistance and damage tolerance. The materials have a unique layered structure that spirals around the part, rather than being flat. This helical architecture allows for more design freedom and tailoring of the composite properties. The helical layup can be made using thin ply unidirectional (TPUD) fabric, thin ply woven fabric (TPW), or quasi-unidirectional woven fabric (QUDW). The helical layup provides better impact resistance compared to traditional flat layups because it allows for more controlled fiber orientation and delamination prevention.

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Splicing composite core structures with different cell sizes to join net edge composite cores without using fillers, foams, or expanding adhesives. The method involves aligning facets of the cells from each core to maximize contact, then connecting them together. This allows seamless integration of cores with varying cell sizes without adding weight or compromising venting. It involves using custom tooling during core fabrication to integrate the transition into the basic production process.

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High-performance glass fiber for applications like wind turbine blades with improved strength-to-weight ratio. The glass composition has a specific modulus (stiffness/weight) that is 15-25% higher than conventional E-glass fibers. The composition contains lithium oxide (Li2O) along with higher levels of magnesium oxide (MgO) and alumina (Al2O3) than traditional glass fibers. The lithium and rare earth oxides (Y2O3, La2O3, Ce2O3) improve fiber properties like elastic modulus and strength while maintaining good forming properties.

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A literature review about polymer composites reinforced with natural fibers reveals a growing academic interest in the topic over past few years. This is due, part, to satisfactory mechanical properties that these multiphase materials have presented tests. In addition, necessity use biodegradable and sustainable has increased recently. this context, lignocellulosic stand out as dispersed phase composites, which providing good strength, are low-cost widely available. Aiming deal two of nowadays greatest global challenges: reduction greenhouse gas emissions into atmosphere greater eco-friendly industry, research objective mechanically characterize epoxy matrix ramie woven fabric medium high theoretical volume fractions fiber (40%, 50%, 60%) through bending tensile tests, order provide data suitable for prior structural analysis evaluate potential application biocomposites horizontal axis wind turbine (HAWT) towers. The statistical analyses carried experimental measurements revealed promising laminated did not undergo ultraviolet condensation aging process (intact specimens).

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A literature review about polymer composites with natural fibers as dispersed phase reveals how widely these multiphase materials have been studied in the last years due to many advantages. In context of renewable energy industry use eco-friendly their components ensure an even more competitive and greener production, this research aims evaluate potential applying epoxy medium high volume fractions ramie woven fabric horizontal axis wind turbine towers. To support study, experimentally determined bending tensile properties referred biocomposites were used some linear structural approaches analyzed. end, it was obtained a given mechanical utilization reinforced considering preliminary analysis developed.

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High-performance glass fiber for wind turbine blades and other applications with improved strength and stiffness. The glass composition has a unique oxide composition with lithium, rare earths like yttria and ceria, and higher magnesium and alumina levels. The glass fibers formed from this composition have elastic moduli of 88-115 GPa and tensile strengths above 4,400 MPa. The high strength allows longer wind turbine blades without excessive flexure. The composition also has favorable forming properties like lower fiberizing temperature and liquidus temperature.

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Weight-reduced fiber-reinforced composite materials and a method to make them. The composites have hollow particles with shells made of a resin containing a high percentage (80%+) of crosslinking monomers. The shells tightly network crosslinked monomers to prevent collapse during composite processing. The hollow particles are made by suspending monomer droplets in water, polymerizing them, then adding a hydrophilic monomer and further polymerizing. This keeps the particles buoyant during composite impregnation. The composite method involves impregnating reinforcing fibers with the resin containing the hollow particles and solvent.

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High-performance glass compositions for making stronger, lighter glass fibers for reinforcement applications like wind blades and composites. The glass composition has specific element ratios and limits on lithium content. It allows forming glass fibers at lower temperatures while maintaining favorable mechanical properties like high modulus and strength. The composition is SiO2-rich, has Al2O3/MgO < 2, and low LiO2.

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Method of manufacturing embedding elements for wind turbine blades that provides stronger root connections and reduces waste compared to known methods. The embedding elements are made by compacting fiber material between movable cores in a mold and then curing. The cores have convex lateral surfaces that compress and shape the fiber. This avoids machining the entire surface and reduces waste. The embedded elements are used in the blade root to secure the blade to the hub. The elements are alternately placed between fasteners in the root region, allowing access to the fasteners. This provides better retention and transfer of loads compared to just using bushings. The embedded elements follow the root circumference and engage the fasteners. The fiber material between the elements is cured to fix them in place.

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Composite layered multi-body support structure for utility lines and substation structures that provides improved strength, resiliency, weight reduction, and conductivity compared to traditional wood, steel, and concrete structures. The structure has concentrically nested elongated composite bodies with varying lengths. This layered design allows balancing of lifting points, reduces weight, prevents decay/corrosion, and reduces electrical conductivity compared to solid composite structures.

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Polished structural insulative lightweight concrete composed of recycled materials. The concrete has a unique composition and manufacturing process to achieve low weight, high strength, insulation, and polishability. It uses calcium sulfoaluminate (CSA) cement, lightweight foamed glass aggregates (FG-LWA), and a grout with Portland cement. The CSA cement provides strength and low shrinkage. The FG-LWA replaces traditional aggregates for lightweight. The grout fills voids between CSA and FG-LWA. The concrete can be polished to a reflective finish.

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A lighter weight blade tip design for turbine blades that reduces weight without using lighter and more expensive materials. The blade tip has a reduced thickness near the tip compared to the root section. This taper gradually transitions the thickness from the root to the tip. This shape reduces weight without sacrificing strength. It allows the blade to maintain load capacity while shedding excess material and weight in the thinning tip section.

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Composite manufacturing method using porous materials like nanofibers, aerogels, and porous films to reduce voids and improve properties in composites. The method involves sandwiching a porous material between layers of fiber-reinforced matrix during curing. The porous material promotes capillary action that draws resin into voids, reducing void content. The porous material can also reinforce the matrix and improve interlaminar properties.

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Tower structures, like wind turbine towers, manufactured using additive printing techniques to enable on-site construction of tall towers without transportation limitations. The towers have walls printed with variable-width deposition nozzles to create voids between layers. Reinforcement members are placed in these voids, closer to the neutral axis than the wall surfaces, for improved structural integrity. This allows optimized placement of reinforcement without needing thicker wall sections. The variable-width nozzle allows customizing deposition paths to form the voids.

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Composite core material for lightweight, high-strength structures like panels that can replace heavier materials like wood in applications like transportation, construction, and aerospace. The composite core material is made by mixing microspheres (solid or hollow) with an encapsulating resin. When cured, it forms a lightweight core material that retains the strength of the resin. The microspheres provide low density and prevent resin flow during molding. The encapsulating resin can be a polyester, vinyl ester, or fire retardant resin.

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A floating platform for offshore wind turbines that has a lower weight and is easier to manufacture and assemble compared to existing floating wind turbine platforms. The platform is a semi-submersible design with a central column, three radial beams, outer columns, and top beams forming a triangular structure around the central column. This triangular frame provides stability and support for the wind turbine tower. The radial beams connect the outer columns to the central column. The semi-submersible design allows the platform to float on water without fixed foundations. It reduces weight compared to conventional steel or concrete floating platforms. The modular triangular frame allows easier assembly and transportation compared to complex shaped floating platforms.

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Method for manufacturing composite blades with internal cavities that prevent resonance and vibration issues. The method involves creating a core with a reinforcing structure occupying only a portion of the core volume. The core has a sealing envelope defining the outer surface. A composite skin is formed around the core. The skin can be made by injecting resin into a fiber preform covering the core, or by laying fiber layers around the core. The core shape, reinforcing structure, and sealing envelope are designed to support the blade while minimizing mass. The core can be made in steps or as a single piece using additive manufacturing. This prevents resin creep into the core and prevents voids. The core with encapsulated reinforcing structure is then wrapped in composite material to make the final blade.

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Reducing weight of wind turbine blades while improving stability at the trailing edge. The blade has a lightweight trailing edge structure that uses internal reinforcements instead of adding weight to the skin. The reinforcements have the same cross-section as the hollow trailing edge region. They are inserted between the upper and lower blade shells during manufacturing. This provides internal support to prevent instability and failure of the thin trailing edge. The reinforcements are combined with a fiber fabric and resin-infused during curing to integrate them into the blade.

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High-strength carbon fiber material for wind turbine blades that provides improved strength-to-weight ratio compared to conventional carbon fiber composites. The carbon fiber material for wind turbine blades includes a specific composition of carbon fiber, resin, rubber powder, nanoparticles, and curing agents. The exact parts by weight of each component are: - Carbon fiber: 50-70 parts - Polyolefin resin: 10 parts - Rubber powder: 20-30 parts - Nanoparticles: 5-10 parts - Triethylenetetramine: 3-5 parts - Epoxy resin: 30-50 parts - Curing agent: 30-50 parts The carbon fiber composite for wind turbine blades also includes a specific sequence of steps to prepare the composite

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A hybrid composite main beam for wind turbine blades that improves stiffness and reduces carbon fiber content compared to pure carbon fiber beams. The hybrid beam uses stacked layers of carbon and glass fiber pultruded plates that are mixed and connected in specific ways. This allows customizable mixing ratios and configurations to optimize stiffness and performance. A first infusion material infiltrates the carbon and glass plates. The hybrid layup provides better performance than monolithic carbon beams while using less expensive glass fiber. The hybrid beam can be prefabricated separately and then inserted into the blade mold for final infusion.

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Wind turbine blade composite material that balances strength, toughness, fatigue resistance, and weather resistance for blades. The composite uses a specific weight ratio of carbon fiber, ultra-high molecular weight polyethylene (UHMWPE) fiber, and epoxy resin. The UHMWPE fiber provides toughness and impact resistance while the carbon fiber provides strength. The epoxy resin binds the fibers together. The weight ratio of carbon fiber:UHMWPE fiber:epoxy resin is 570:5-10:100 by parts.

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