Together with the DLR in Stade (German Aerospace Center), the project partners SAERTEX and Covestro have set themselves a challenging task: The infusion of a 45 m long spar cap for a rotor blade. Unlike usual, however, no epoxy resins were used, but a newly developed PU resin from Covestro.
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Objective
Covestro developed an innovative polyurethane resin to shorten process times in rotor blade production and improve the mechanical performance of large-format composite components. The overarching goal: advanced material solutions that help to reduce production costs and strengthen the competitiveness of wind energy compared to conventional energy sources.
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Optimized flow properties for faster and more efficient infusion processes
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Improved mechanical performance, especially in terms of fatigue strength
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More InformationSAERTEX brought infusion-optimized glass fibre fabrics (NCF) and the structural core material SAERfoam into the project as a sustainable alternative to balsa. By precisely matching the textile reinforcement materials to the new PU resin, it was possible to achieve uniform impregnation over the entire component length of 45 meters.
In addition, SAERTEX supported the process development with its extensive know-how and many years of experience in the wind energy sector. This close cooperation between material development and application practice was a decisive factor for the success of the project.
The successful infusion of the 45 m long Sparcap shows that PU-based composites can make the production of rotor blades more efficient, more powerful and more economical. A joint advance for more competitive wind energy.
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