3TEX 3D Fiber Systems for Wind Blades

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1 3TEX 3D Fiber Systems for Wind Blades RapidRoot3D TM Preforms- eglass up to.3in (8mm) thick. Custom Woven/Formed to Spec/Diam Build Root Fast, and Infuse Faster. 20 plies or less => +4in (100mm) thick. Click for more 3TEX UniGirder TM Spar cap. Entire spar cap woven in single layer. Glass or Carbon, 90% Uni Very Fast, Very Easy, E11=120GPa+ Tested by NREL Click for more 3WeaveTM Pi-Joints 3D Woven Unfolds to form Gap Tolerant Slip Joint in Single Ply ZPlex Conformal Sandwich Preform Compound Curves &NO core bond line. Skins- 90% 0/ % +/-45 Core- 25%Zfiber+75%+/-45deg Shear YZ psi (2700kPa )& Z tens 360psi+ (2700+kPa) CLICK FOR MORE FilletBraidTM Shaped Glass Gap/Joint/Corner Preforms 100% glass VARTM Wet Lay Joints CLICK MORE

2 Pre-Kitted On-Loom for Root Construction 3TEX Looms working hard to make your job Easy Girder 0,90, Mats, and/or +/- 45deg avail. Rolls or Semi-Rigid Arcs Easy to Ship, Store, Handle, and Automate If Arcs - Woven Pre-Curved to Root Diam Woven to Recipe and Dimensional Spec Girder Length Set by Strip Width Hoop Circumference Set by Cut Off Insures ply drops to your spec. Rapid Fiber Placement Fiber Orientation Recipe to Your Spec. 0,90, Mats, and/or +/- 45deg avail. Ply Tapers Woven-In on Loom Smooth out ply drops Sample upto roll Construction 100 in length girder hoop total thick (mm) thick (in) % 17% 49% 17% oz/yd g/m As Woven Preform shows No Droop under its own weight over 12in cantilever Curved panels stable from roll to mold.

3 RapidRoot 3D Infusion Faster Resin Flow, Never a Dry Spot, and No Sacrifice in Performance 5min 2.5min 2M Diam x NO INFUSION MEDIA NEEDED 1.1m Spanwise x 85mm thick RapidRoot Preforms are woven with organized resin flow paths Girder Hoop* ResinFlow Optimized Resin flow paths speed flow spanwise and eliminate infusion Media.

4 RapidRoot 3D - Mech. Performance Faster Resin Flow, Never a Dry Spot, and No Sacrifice in Performance 3TEX Rapid Root Prelim Mech Test Data Testing Provided by PPG Fiber Science & Technology Center - Shelby NC 3TEX Composite 2 ply RapidRoot 4.2mm Style PCF SE1200 Girder 3Tex Composite 1 ply RaidRoot 8.5mm Style P3W-P HX5 SE1200 Girder **note that with 1-2 plies +/-45 are at surface while Hoop and Girder are near neutral axis as such EI for thin flex test may not be representative of full root section Laminate Construction 8/28/2009 panels prepared by vacuum infusion using PPG Lab Designation Ashland AME inf vinylester resin g/m2 w% g/m2 w% Total % % Girder % % Hoop* % % % % % % *Zfiber is <2% of total wgt and is attributed to Hoop Tensile ISO Method Units (ISO) % Glass Content (Avg) ISO 1172 Wgt% 76.1% 72.44% % Resin Content (Avg) ISO 1172 Wgt% 23.9% 27.56% % Void Content (Avg) V% 1.5% -0.1% Resin Density Manf Spec. g/cm % Glass Content (Avg) Calc from W% Vol% 57% 54% Tensile Strength - Girder (Avg) ISO MPa Tens Modulus ISO ,290 29,030 COV Tens Mod ISO % 6.3% Tensile Strength - Hoop (Avg) ISO MPa Tens Modulus ISO ,960 18,660

5 RapidRoot3D Variants RapidRoot3D gsm Delivered in ROLL or Arc'd Preforms girder hoop Vf% 33% 67% 50% 33% 0% 50% 17% 100% ratios thick mm 1, , ,400 g/m oz/yd thick in RapidRoot3D gsm Delivered as Semi-Rigid Arc'd Preforms girder hoop Total Vf% 35% 65% 49% 17% 17% 50% 15% 100% ratios thick mm 1,800 1,800 5,209 1,600 10,409 g/m oz/yd thick in Recipes at left have been produced to customer specification. Nearly any preferred thickness or orientation ratios can be provided. All preforms avail with woven-in 10:1 ply drop tapers and are supplied to ordered dimensions.

6 Woven to Full Width and Thickness Specified 2-20mm Thick 29Plies x 26ozUni 754oz 2X final thickness Industrial Uni-Axials : Infusion Demo ONE Ply UniGirder 751oz within 10% of final thickness Same Fiber Type Same Surface Sizing Same Total Fiber (750oz/yd2) Same Resin Supply Same Vacuum Supply Z-axis Resin Flow Paths Elevator Shafts 88-93% 0deg Glass, Carbon, other 00:00:00 Glass Filling 29plies 26oz Uni Single Ply of Uni Girder Tool still dry 29plies 26oz Uni Tool still dry 00:00:18 00:01:04 Tool Face Wet in 18 seconds UniGirder preform had 1000s of elevator shafts wet every level of the.7in (18mm) thick stack in under 70 seconds. Glass Z VERY Different Result One Ply to Lay Up Almost NO debulk. and you get elevator shafts?

7 3Tex UniGirder 3Dwoven 371 oz/yd2 88%fiber in X (warp) axis by wgt (5% in Y 7%in Z) 00:04:07 no need to sacrifice Fiber and Properties to get Flow. Units (ISO) value Flexural Strength - Warp (Avg) MPa Flexural Strength - Warp (COV) % 4.12 Flexural Modulus - Warp (Avg) MPa Flexural Modulus - Warp (COV) % 5.61 Flexural Strength - Fill (Avg) MPa Flexural Strength - Fill (COV) MPa 11 Flexural Modulus - Fill (Avg) MPa Flexural Modulus - Fill (COV) % 4.34 Tensile Strength - Warp (Avg) MPa Tensile Strength - Warp (COV) % 5.36 Tensile Modulus - Warp (Avg) MPa Tensile Modulus - Warp (COV) % 2.68 Tensile Strength - Fill (Avg) MPa Tensile Strength - Fill (COV) % 5.1 Tensile Modulus - Fill (Avg) MPa Tensile Modulus - Fill (COV) % 2.54 Tensile Break, Dry (Avg) % Tensile Break, Dry (COV) % 7.54 Short - Beam Shear, Panel (Avg) 7.41 Short - Beam Shear, Panel (COV) % 2.03 Short-Beam Shear, Panel, Fill (Avg) 2.3 Short-Beam Shear, Panel, Fill (Cov) 6.73 % Glass Content (Avg) W% 75.5% % Resin Content (Avg) W% 24.5% % Void Content (Avg) W% -1.2 % Glass Content (Avg) Vol% 58% All the Fiber, All the Performance a fraction of the time. ECR, Boron-Free, and Carbon Fiber Styles Avail up to 130GPa

8 3TEX UniGirder 3D 1Ply, 1cut, 2 parts = Fast and Error Free Infusion Single-Ply Spar Caps US Pat Single Ply- Full Thickness,Width-Tapered, Optimized to Spec. Blade. 1 cut=2 Caps -Minimized Waste, Speeds Lay up, and Eliminates Error. Loading of tool is VERY rapid and consistent

9 Testing of 9m Blades with 3TEX Carbon Spar Cap Note 90-94% axial fraction now avail will proportionally increase modulus Area Distribution of Fiber Jeffco Modar Thick Weight Weight % Product ID mm g/m 2 X Y Z E 11, Gpa E 11, Gpa (0deg) (90deg) P3W-HX P3W-HX D Woven Carbon/Glass Hybrid Spar Cap for Wind Turbine Rotor Blade Journal of Solar Energy Engineering -- November Volume 128, Issue 4, pp All Blades from same mold. ERS-100 Rev B 3TEX 3X-100 CX-100 Property 2D Glass 3D Carbon 2D Carbon Weight (lb) Root Failure Moment (kn-m) A full set of 9m blades with 3TEX single ply spar caps were heavily instrumented and have been power tested at the USDA Agriculture Research Service (ARS) center in Bushland, Texas, on a Heavily Instrumented 115 kw Micon 65/13 Stall regulated turbine with, Nacelle acceleration detection, Tower instrumentation, and Inflow Arrays. Frequency, stall, and power data showed no stall at low wind speeds, and from the PSD plots, the material being tested has good damping, better than equivalent fiberglass, and it did not excite any of the fundamental frequencies. SAND Static and Fatigue Testing performed by NREL and Sandia NL has verified the predictability and performance of blades manufactured using the 3TEX single ply spar cap system relative to traditional glass and carbon spar baselines.

10 FilletBraid TM Bridging the Gaps. Conforms to variable gaps like cotton balls but it s eglass FIBER 100% Glass (50% Lofted) Through thickness fiber Transfers Loads Through Joints Tight corners Dry for VARTM Variable Gaps / Joints WET HAND Lay Eliminates: fabric bridging, Resin Pockets, Exotherms, Puttys, Adhesives, CTE misfits, Excess Shrinkage Many shapes/sizes 3mm to 30mm.

11 Woven Joining Elements Preforms Woven in the SHAPE of the JOINT to be formed for faster, more secure joint formation. Thickness of Bond Line Less Critical Trapped Adhesives Forced Around Web Even Interlock with Core trusses if you use ZPlexTM Web

12 ZPlex TM Patents Pending Conformal Total Sandwich Preforms Inert and Conformable PE Foam Compound Curves and NO skin/core Bond Lines. No Delamination ever. Fiber Trusses bear all Loads. Infusion paths woven in. Tongue and groove edges enable large/long parts. Certain Variants of ZPlex TM include angled structural core fibers to cross-brace the sandwich in the Y-Z and X-Y planes. The Columns brace and tie the skins. Adhesives Enter and Interlock with Core trusses fasten just one skin, Delamination is entirely suppressed.

13 ZPlex R Strength X vs Y In-plane fiber content of the skins are very nearly equal, so the tensile behavior in X and Y should be much the same. However, the Z-columns and resin films between them are shaped so that extra shear strength and stiffness is gained in the Y direction which improves flexure in that direction. The shear strength in the Y-Z plane can be 2X to 3X that of the X-Z plane. In the angled fiber version shown below, shear strength has been measured at 80psi (550kPa) in X-Y and 300+psi (2060kPa) in Y-Z. This is comparable to 4pcf (65kg/m3) in X and 12pcf (200kg/m3)in Y, The difference is explained below and should noted when selecting the style and orientation of the parts produced. Compression Strengths are generally over 350psi (2360kPa) in most styles. Z Y X

14 ZPlex vs 80kg (6lb) xl PVC. 3Pt Bend wide format Thanks to Aptera 3pt bend Span=11.5in. Width =12in min Strength Y Strength X thick Composite Wgt lbf/in-width lbf/in-width Core Type oz/yd2-core-oz/yd2 style in lb/ft Zplex HX /2-54 HX diab 50-1/2-50 h80 pvc Despite the H80 PVC based sandwich being thicker, the ZPlex panel sustained 2x the load. The thicker H80 foam would reasonably be expected to provide strength 36% higher in the, which actually implies a greater advantage to the ZPlex. Force (lbf) ASTM6416-Hydromat - Force vs Displacement ZPlex in -0.2 ZPlex in Center Disp (inches) -0.3 H80pvc.363in -0.4 H80pvc.605in -0.5 ZPlex in ASTM D6416 Hydromat Diaphragmatic Testing Thanks to Gougeon Bros x 12.0 ZPlex panels & h80 pvc foam core panels, all with eglass skins, were tested by Hydromat method with a support span of inches. The upper limit of 6500lbf for the load cell forced termination of testing prior to failure on several ZPlex styles. ZPlex kept taking more load after thicker foam gave up..605 thick H80 PVC 2300lbf while thinner.514 thick ZPlex took 5000lbf with no yield..375in ZPlex beat.363inpvc soundly.