INFUSION OF A 45 M LONG ROTOR BLADE SPAR CAP WITH PU RESIN

In collaboration with the DLR (German Aerospace Center) in Stade, the SAERTEX project partners and Covestro set themselves an ambitious task: the infusion of a 45 m long spar for a rotor blade. Unlike usual, it wasn't epoxy resins that were used, but a PU resin newly developed by Covestro.

The idea

Covestro has developed an innovative polyurethane resin to reduce processing times in rotor blade production and improve the mechanical performance of large-format composite components. The overall aim: advanced material solutions that help reduce production costs and boost the competitiveness of wind power compared with conventional energy sources.

reinforcing this idea

SAERTEX contributed to the project by supplying infusion-optimized glass fiber fabrics (NCF) and the structural core material SAERfoam as a sustainable alternative to balsa. Thanks to the precise adaptation of the textile reinforcement materials to the new PU resin, it was possible to achieve uniform impregnation along the entire length of the 45-meter component.

In addition, SAERTEX supported the process development with its extensive know-how and many years of experience in the wind energy sector. This close collaboration between material development and application practice was a decisive factor in the project's success.

Technical advantages

1. Optimized flow properties for faster and more efficient infusion processes
2. Improved mechanical performance, especially in terms of fatigue strength

The success story

The successful infusion of the 45-meter spar cap demonstrates the potential of PU-based composites to improve processing speed, part performance and overall cost-efficiency in wind energy applications. A joint advance for more competitive wind energy.