A pre-form and a method of preparing pre-forms are provided. The pre-forms comprise a resin and at least two layers of oriented fiber tows. The pre-forms comprise fiber tows instead of the traditional prepregs to enhance rearranging of resin and/or fibers during subsequent processing as well as prov
A pre-form and a method of preparing pre-forms are provided. The pre-forms comprise a resin and at least two layers of oriented fiber tows. The pre-forms comprise fiber tows instead of the traditional prepregs to enhance rearranging of resin and/or fibers during subsequent processing as well as provide greater freedom, a price reduction and/or a reduction of waste. The pre-forms may be formed three-dimensionally to enhance coupling to further pre-forms or other structures and/or to enhance shaping of the pre-form to a final three-dimensional shape. The method of preparation of pre-forms involves providing an adhesive between layers of fibers and providing a resin in contact with at least one of the layers of fibers. The resin is preferably provided in a non-continuous layer to allow for removal of gas at least partially in a direction orthogonal to the layers of resin. Advantageously, during manufacturing, the fibers are placed with an exact start and ending location, thereby avoiding waste. The pre-forms are suitable for preparation of composite structures like for example spars for wind turbine blades.
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1. A method for preparing a pre-form, comprising: providing layers of oriented fibre tows, wherein a plurality of the layers of fibre tows consist exclusively of unidirectionally oriented, continuous fibres;providing an adhesive between the layers of fibres to at least partially immobilize the fibre
1. A method for preparing a pre-form, comprising: providing layers of oriented fibre tows, wherein a plurality of the layers of fibre tows consist exclusively of unidirectionally oriented, continuous fibres;providing an adhesive between the layers of fibres to at least partially immobilize the fibres; andproviding a resin in contact with at least one of the layers of fibre tows, the resin consisting essentially of a thermosetting material and containing no thermoplastic materials,wherein at least one of the layers of oriented fibre tows is positioned off the edge of a preceding layer of oriented fibre tows so that the pre-form is tapered.wherein the adhesive is provided in a non-continuous layer between adjacent layers of fibres, thereby forming gas escape pathways having pathway outlets directed in at least two orthogonal directions, the at least two orthogonal directions being transverse to the unidirectional orientation of the fibres such that the at least two orthogonal directions include a primary orthogonal direction oriented through a thickness defined by the layers of oriented fibre tows in combination and a secondary orthogonal direction oriented parallel to the plurality of the layers of oriented fibre tows, and such that the gas escape pathways promote gas escape during curing or pre-curing of the resin and adhesive in the at least two orthogonal directions through the pathways outlets. 2. The method of claim 1, wherein the resin is initially provided as a liquid. 3. The method of claim 2, wherein the liquid resin forms an oriented or random pattern of a line, several lines or dots. 4. The method of claim 1, wherein gas can escape during a pre-consolidation process so that no gas is present in the pre-form prior to consolidation or curing of the pre-form. 5. The method of claim 1 , wherein the resin is a liquid which forms a random pattern or a combination of a random pattern and an oriented pattern. 6. The method of claim 1, wherein the resin is provided in a non-continuous layer that is formed from a continuous layer which subsequently has a plurality of through-going holes introduced therethrough. 7. The method of claim 1, wherein providing the layers of oriented fibre tows comprises providing the layers of oriented fibre tows to form a desired orientation or form of ground plan, by selectively cutting or initiating fibres during fibre layout. 8. The method of claim 1, wherein the fibre layers are provided within an area defined by a preceding fibre layer by selectively cutting or initiating fibres. 9. The method of claim 1, wherein the layers of oriented fibre tows have substantially the same size as a preceding fibre layer off the edge of a preceding fibre layer, thereby simultaneously realizing at least two tapered parts of the pre-form. 10. The method of claim 1, wherein the resin is provided between two layers of fibre tows. 11. The method of claim 1, wherein the adhesive comprises at least one of the components of the resin. 12. The method of claim 1, wherein the resin is provided as solid or semisolid particles. 13. The method of claim 1, wherein the resin is substantially epoxy-based. 14. The method of claim 13, wherein the resin comprises two epoxy-based systems. 15. The method of claim 14, wherein the epoxy-based systems comprise different amine components, wherein an amine component of a first epoxy-based system will react with an epoxy component at a first temperature, whereas an amine component of a second epoxy-based system will be mainly un-reactive at the first temperature. 16. The method of claim 15, wherein the amine component of the second epoxy-based system will cure upon activation of a corresponding catalyst. 17. The method of claim 14, further comprising the step of preparing a pre-mix comprising amine components and catalyst to form a stable fluid or slurry. 18. The method of claim 17, further comprising the step of preparing a resin mixture comprising the pre-mix and an epoxy component immediately before applying the resin mixture for preparing a pre-form. 19. The method of claim 1, wherein the resin is semisolid at room temperature. 20. The method of claim 1, wherein the layers of oriented fibre tows are prepregs. 21. The method of claim 1, wherein the step of providing layers of oriented fibre tows further comprises: providing layers of oriented fibre tows including first type fibres, a part of the pre-form being formed three-dimensionally so that said part of the pre-form is tapered along a connection surface defined by terminal ends of the layers of oriented fibre tows that include first type fibres; andproviding layers comprising second type fibres different than the first type fibres, and wherein layers having an appreciable amount of, or exclusively containing the second type fibres are interlaced between layers having an appreciable amount of, or exclusively containing the first type fibres such that the layers containing second type fibres are separated from one another by the layers containing first type fibres, wherein the second type fibres extend from within the pre-form beyond the connection surface of the pre-form,wherein the second type fibres do not contain the same fibre material as the first type fibres such that the pre-form is enhanced for coupling at the connection surface to a composite member comprising the second type fibres and a resin, the second type fibres positioned to extend into the pre-form on one side of the connection surface and extend into the composite member comprising the second type fibres on another side of the connection surface. 22. The method of claim 1, wherein the adhesive forms lines having an angle relative to a lengthwise orientation of the fibres which is about 90° degrees relative to the lengthwise orientation of the fibres. 23. A method for preparing a pre-form, comprising: providing layers of oriented fibre tows, wherein a plurality of the layers of fibre tows include continuous fibres defining a lengthwise orientation;providing an adhesive between the layers of fibre tows to at least partially immobilize the fibres; andproviding a resin in contact with at least one of the layers of fibre tows,wherein the adhesive is provided in a layer between adjacent layers of fibre tows, thereby forming lines oriented transverse relative to the lengthwise orientation of the fibres and forming gas escape pathways between the lines and having pathway outlets directed in an orthogonal direction, the orthogonal direction being transverse to the lengthwise orientation of the fibres and within the adhesive layer, such that the gas escape pathways promote gas escape during curing or pre-curing of the resin and adhesive in the orthogonal direction through the pathways outlets without requiring the gas to move through the adjacent layers of fibres to escape. 24. The method of claim 23, wherein the adhesive is provided in non-continuous layers. 25. The method of claim 23, wherein the resin consists essentially of a thermosetting material and contains no thermoplastic materials.
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이 특허에 인용된 특허 (17)
Hanson Brad A. (Huntington Beach CA), Closed composite sections with bonded scarf joints.
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