Joining of composite elements of wind turbine blade

Abstract

A method for joining a first composite element (100) and a second composite element (200) of a wind turbine blade includes positioning an edge joining portion (120) of the first composite element (100) having a thermoplastic material facing an edge joining portion (220) of the second composite element having a thermoplastic material, and plastically welding the edge joining portions. Preferably, the method further includes inserting a triangular thermoplastic connector (160) between the composite elements (100, 200), and plastically welding the first side (161) and the second side (162) of the connector to the edge joining portion (120, 220). Although the edge joining portion (120, 220) of the composite blade element is thermoplastic, the remainder of the composite element (100, 200) may comprise a thermoplastic resin or a thermosetting resin. A wind turbine blade is also disclosed comprising a first composite element and a second composite element joined together.

Description

Technical Field

[0001] The present disclosure relates to a method for joining a first composite element and a second composite element of a wind turbine blade, and a wind turbine blade comprising a first composite element and a second composite element joined according to any of these methods. Background Art

[0002] Modern wind turbines are commonly used to supply electricity to a grid. Such wind turbines generally include a rotor having a rotor hub and a plurality of blades. The rotor begins to rotate under the influence of the wind on the blades. The rotation of the rotor shaft drives the generator rotor directly ("direct drive") or through the use of a gearbox. The gearbox (if present), generator and other systems are typically mounted in a nacelle on top of the wind turbine tower.

[0003] A wind turbine blade has a root portion for attachment to a rotor hub and a tip portion at the opposite end. The root portion of a wind turbine blade typically has a generally circular cross-section. Some other regions, such as the profile portion or airfoil portion farthest from the rotor hub, have a cross-section with an aerodynamic profile.

[0004] Wind turbine blades are generally made of fiber reinforced polymers or plastics (FRP), which are composite materials consisting of a polymer matrix and reinforced with fibers. The fibers are typically glass or carbon and provide longitudinal stiffness and strength. The polymer matrix allows the fibers to bind together and increases toughness and delamination strength. The polymer matrix is ​​typically made of a thermosetting material, such as a thermosetting resin.

[0005] Wind turbine blades are usually made by joining several sheets of fiber reinforced polymers (e.g. glass fiber or carbon fiber reinforced polymers). These sheets or segments are first produced and then joined. These sheets can be formed using resin infusion technology or prepreg technology. In resin infusion technology, the fibers are placed in a mold and then resin is injected into the mold cavity under pressure. The resin fills the volume between the cavities and then the resin cures or hardens. Examples of resin infusion technology may be resin transfer molding (RTM) or vacuum assisted resin transfer molding (VARTM). In VARTM, the resin is injected under the action of a vacuum or a pressure below atmospheric pressure.

[0006] The blade shell parts may be formed, for example, by using VARTM technology and then bonded by adhesive. For example, the pressure side blade shell may be bonded to the suction side blade shell by a joining line along the leading edge and the trailing edge. The load bearing structure may be arranged between the pressure side blade shell and the suction side blade shell. The load bearing structure may include opposing spar caps bonded to the respective blade shells.

[0007] In recent years, there has been a trend to increase the size of wind turbine blades to capture more wind. Larger blades may involve larger molds during manufacturing and may complicate the transportation of the blades to the wind turbine site.

[0008] Wind turbine blades may be manufactured in segments to reduce transportation constraints. These blade segments are transported to the wind turbine site and assembled at the site. Connecting these blade segments generally involves adding metal parts to the blade segments and connecting these metal parts together. The metal parts may be bolted or welded. However, the use of these metal parts may increase the weight of the wind turbine blade. In addition, these metal joints may be damaged by fatigue and corrosion.

[0009] The size of the mould can be reduced by using more moulds with reduced size. Thus, a wind turbine blade can be formed by joining several blade parts. For example, a blade shell can be formed by joining a plurality of blade shell parts. These blade parts can be joined by an adhesive or glue. However, the use of an adhesive or glue may require complex preparation of the part to be glued. In addition, the glued joints involve relatively long curing times and, for safety reasons, it is usually necessary to check the glued joints. For this reason, the glued joints in wind turbine blades can be complicated and time-consuming. In addition, the glued joints can be damaged by fatigue and surface degradation, which can adversely affect the bond strength. Cracks can also easily propagate in glue or adhesive joints.

[0010] The present disclosure provides examples of systems and methods that at least partially address some of the above-mentioned shortcomings. Summary of the invention

[0011] In a first aspect, a method for joining a first composite element and a second composite element of a wind turbine blade is provided. Each of the first composite element and the second composite element comprises one or more edge joining portions having a thermoplastic material. The method comprises: positioning one edge joining portion of the first composite element to face one edge joining portion of the second composite element; and plastic welding one edge joining portion of the first composite element to one edge joining portion of the second composite element.

[0012] According to this aspect, composite elements of a wind turbine blade can be joined together in a simple process. Since plastic welding of thermoplastic materials is a relatively simple joining technique, the joining time can be reduced. The method can allow the use of multiple composite elements for manufacturing a wind turbine blade. Each of these composite elements can be molded in a specific mold. As a result, the complexity of the molding process can be reduced. Therefore, longer blades can be manufactured efficiently.

[0013] Furthermore, due to the use of plastic welding, the joint strength can be further increased. The structural integrity of the wind turbine blade can thus be further increased. Adhesive joints can thus be avoided or at least reduced. Stronger joints can thus be obtained and the life of the blade can be extended. Since the adhesive or glued joints are replaced by plastic welding, the overall weight of the wind turbine blade can also be reduced.

[0014] In contrast to thermosetting materials, thermoplastic materials can be melted under heating after curing. The joints of these composite elements can be repaired by melting the thermoplastic material forming the joint again. Thus, maintenance or rebuilding operations of wind turbine blades can be enhanced. Furthermore, thermoplastic materials can also be recycled.

[0015] In another aspect, a wind turbine blade is provided, comprising a first composite element and a second composite element joined according to a joining method according to any of the examples disclosed herein.

[0016] Advantages obtained from this aspect may be similar to those mentioned in relation to the first aspect. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Non-limiting examples of the present disclosure will be described below with reference to the accompanying drawings, in which: Figure 1 shows a perspective view of a wind turbine according to one example; Figure 2 shows a perspective view of a wind turbine blade according to one example; Figure 3 Shows Figure 2 A cross-sectional view of a wind turbine blade; Figure 4 is a block diagram of a method for joining a first composite element and a second composite element of a wind turbine blade according to an example of the present disclosure; FIG5 a schematically presents a first composite element to be joined to a second composite element according to an example of the present disclosure; FIG5 b schematically presents an edge joining portion of the first composite element in FIG5 a facing an edge joining portion of the second composite element in FIG5 a ; FIG. 5 c schematically presents the first composite element of FIGS. 5 a - 5 b plastically welded to the second composite element of FIGS. 5 a - 5 b ; 6a and 6b are examples of a first composite member 100 according to an example of the present disclosure; 7a-7c schematically present joining a first composite element and a second composite element according to an example of the present disclosure, comprising inserting a connector between the first composite element and the second composite element; 8a - 8c schematically present joining a first composite element to a second composite element according to examples of the present disclosure; and Fig. 9 A wind turbine blade comprising a first composite element joined to a second composite element according to an example of the present disclosure is schematically presented. DETAILED DESCRIPTION

[0018] In these figures, the same reference symbols are used to indicate matching elements.

[0019] Figure 1 A perspective view of an example of a wind turbine 1 is shown. As shown, the wind turbine 1 includes a tower 2 extending from a support surface 3, a nacelle 4 mounted on the tower 2, and a rotor 5 coupled to the nacelle 4. The rotor 5 includes a rotatable hub 6 and at least one wind turbine blade 7 coupled to the rotor hub 6 and extending outwardly from the rotor hub 6. For example, in the example shown, the rotor 5 includes three wind turbine blades 7. However, in alternative embodiments, the rotor 5 may include more or less than three blades 7. Each wind turbine blade 7 may be spaced apart from the rotor hub 6 to facilitate rotation of the rotor 5 so that the kinetic energy of the wind can be converted into usable mechanical energy and subsequently into electrical energy. For example, the rotor hub 6 may be rotatably coupled to a generator 10 positioned within or forming part of the nacelle 4 to allow electrical energy to be generated.

[0020] The blade 7 is coupled to the rotor hub 6 using a pitch bearing located between the blade 7 and the rotor hub 6. The pitch bearing comprises an inner ring and an outer ring (shown). The wind turbine blade can be attached to either the inner bearing ring or the outer bearing ring, while the hub is connected to the other. When the pitch system is actuated, the blade 7 can perform a relative rotational movement relative to the rotor hub 6. Thus, the inner bearing ring can perform a rotational movement relative to the outer bearing ring.

[0021] Figure 2 An example of a wind turbine blade 7 is shown. The wind turbine blade 7 extends in a longitudinal or spanwise direction 37 from a blade root end 71 to a blade tip end 72. The blade 7 comprises a blade root region or portion 50 closest to the rotor hub, a profile portion or airfoil portion 52 furthest from the rotor hub, and a transition portion 51 between the blade root portion 50 and the airfoil portion 52. The blade 7 comprises a leading edge 53 facing the direction of rotation of the blade 7 when mounted on the rotor hub, and a trailing edge 54 facing in the opposite direction of the leading edge 53.

[0022] In the example disclosed herein, the length of the wind turbine blade 7 from the blade root end 71 to the blade tip end 72 is more than 60 meters, for example more than 100 meters. However, wind turbine blades 7 of any length may be used.

[0023] The airfoil portion 52 has a shape designed to generate lift, while the blade root portion 50 has a circular or elliptical cross section for structural considerations and to facilitate mounting the blade to the rotor hub. The diameter or chord of the blade root portion 50 may be constant along the entire blade root portion 50. At the transition portion 51, the profile gradually changes from the circular or elliptical cross section of the blade root portion 50 to the airfoil profile of the airfoil portion 52.

[0024] The wind turbine blade 7 comprises a blade shell 73. The blade shell 73 comprises an outer side or outer surface defining the outer shape of the blade, such as the outer shape at the blade root portion and the outer shape at the airfoil portion. The blade shell 73 also comprises an inner side or inner surface defining the inner volume of the blade and facing the load-bearing structure (not shown). The blade shell 73 may be made of a fiber-reinforced polymer or plastic, such as glass fiber and / or carbon fiber.

[0025] The blade shell may be formed from a plurality of blade shell parts. A plurality of blade shell parts may be joined together to form the blade shell. The blade shell parts may be formed according to any example disclosed herein and subsequently joined. Resin infusion techniques (e.g. RTM or VARTM) or prepreg techniques may be used to manufacture the blade shell parts.

[0026] In some examples, the blade shell portions are arranged in a lengthwise end-to-end configuration.In some examples, two or more blade shell portions are arranged between the leading edge and the trailing edge.

[0027] In some examples, the blade shell includes a pressure side blade shell portion and a suction side blade shell portion. The pressure side blade shell portion may be joined to the suction side blade shell portion along a joining line (which is along the leading edge 53 and the trailing edge 54). The pressure side blade shell portion and / or the suction side blade shell portion may be formed by joining a plurality of blade shell portions.

[0028] The blade shell portion of this example includes a composite material. The composite material may include reinforcing fibers and a resin. The reinforcing fibers may be glass fibers, carbon fibers, aramid fibers, or basalt. The resin of this example may be a thermoplastic resin, or a thermosetting resin. Examples of thermosetting resins may include epoxy resins, polyester resins, or vinyl ester resins.

[0029] In some examples, the blade shell portion is formed of a composite material. The laminate material may include multiple layers of reinforcing fibers embedded in a resin. The orientation of the fibers in each of the layers may vary. For example, some layers include unidirectional fibers and other layers include biaxial fibers. Some layers may also include triaxial fibers. The laminate composite material may include a thickness between 20 mm and 80 mm.

[0030] In some examples, the blade shell portion includes a core material arranged between laminated composite materials. The core material generally includes a lightweight material, such as wood (e.g., balsa wood), foam (e.g., extruded polystyrene foam), or any combination thereof. The thickness of the core material may be between 20 mm and 100 mm. The thickness of the laminated composite material surrounding the core material may be according to any of the examples disclosed herein. Such a blade shell portion may be referred to as a sandwich panel.

[0031] Figure 3 Shows Figure 2 A suction side 57 and a pressure side 56 extend from a leading edge 53 to a trailing edge 54. The wind turbine blade 7 further comprises a chord line 38 between the leading edge 53 and the trailing edge 54. The chord line 38 extends in the edgewise direction.

[0032] The wind turbine blade 7 includes a blade structure that provides stiffness to the wind turbine blade. The blade structure of this example includes a blade shell 73 and a load-bearing structure. In other examples, the blade structure may also include a plurality of structural ribs arranged along the length of the blade. In this example, the load-bearing structure includes shear webs, such as a leading edge shear web 43 and a trailing edge shear web 44. The load-bearing structure of the figure also includes a pressure side spar cap 74 arranged at the pressure side 56 and a suction side spar cap 76 arranged at the suction side 57. In some examples, the shear webs 43 and 44 may be spar boxes having spar sides (such as a trailing edge spar side and a leading edge spar side).

[0033] The spar caps of this example are formed of a composite material (e.g., reinforcing fibers and resin). The spar caps may include a laminated composite material, i.e., layers of reinforcing fibers. The spar caps are attached to the blade shell. In some examples, the spar caps include a plurality of spar cap portions extending edge to edge in a lengthwise direction.

[0034] According to any of the examples disclosed herein, the spar cap may be joined to the blade shell.

[0035] Figure 4 1 is a block diagram of a method for joining a first composite member and a second composite member of a wind turbine blade according to an example of the present disclosure. The first composite member includes one or more edge joining portions. The second composite member also includes one or more edge joining portions. The edge joining portions include a thermoplastic material. In some examples, the edge joining portions may include reinforcing fibers and a thermoplastic resin. The reinforcing fibers include glass, carbon, aramid, and / or basalt.

[0036] Thermoplastic materials allow for plastic welding of composite elements. In some examples, the thermoplastic material comprises a thermoplastic resin. The structural properties of the thermoplastic resin may be at least similar to those of a thermosetting resin, such as an epoxy resin. Examples of thermoplastic materials are polystyrene, poly(acrylonitrile butadiene styrene), poly(acrylonitrile styrene acrylate), poly(styrene acrylonitrile), polycarbonate, polyetheretherketone, polybutylene terephthalate, thermoplastic elastomers, or any combination thereof. The selected thermoplastic material (e.g., thermoplastic resin) comprises a melting point above 60°C. In some examples, the thermoplastic material (e.g., thermoplastic resin) comprises a melting point above 100°C, such as above 120°C. Thus, when the wind turbine blade is in operation, the thermoplastic material may remain solid, i.e., not melt.

[0037] The first composite element and the second composite element may be blade shell parts and / or spar cap parts. For example, the first composite element may be a first blade shell part and the second composite element may be a second blade shell part. In other examples, the first composite element is a first blade shell part and the second composite element may be a spar cap part. In further examples, the first composite element may be a first spar cap part and the second composite element may be a second spar cap.

[0038] These composite elements may comprise laminated composite materials. In some examples, a core material is arranged between two laminate sheets forming a sandwich panel.

[0039] In some examples, the first composite element includes a main portion attached to one or more edge connecting portions. The main portion includes reinforcing fibers and resin. Alternatively or in addition, the second composite element includes a main portion attached to one or more edge connecting portions. The main portion and the edge connecting portion can be molded and infused together.

[0040] Method 900 includes positioning one edge joining portion of the first composite element to face one edge joining portion of the second composite element as presented at block 910. Thus, the first composite element and the second composite element may be arranged at a position suitable for plastic welding. Thermoplastic material of the corresponding edge joining portion may be at least partially melted to join the two composite elements.

[0041] In some instances, at least one zone of the edge joining portions is arranged to contact. In some instances, positioning 910 an edge joining portion of the first composite element to face an edge joining portion of the second composite element includes positioning the edge joining portions in a butt weld configuration. The first composite element and the second composite element are placed end to end, wherein the corresponding edge joining portions have thermoplastic materials facing each other. In some instances, the edge joining portions are substantially straight. In other instances, the edge joining portions are beveled. In these instances, the first composite element and the second composite element can be arranged in a U-shaped groove or a V-shaped groove configuration. For example, a butt weld configuration can be used to plastically weld blade shell portions.

[0042] In other examples, the first composite element and the second composite element may be arranged in a lap weld configuration. The edge joining portion of the first composite element may overlap the edge joining portion of the second composite element. This weld configuration may be used for plastic welding of the blade shell portion and the spar cap portion.

[0043] Additionally, method 900 includes plastic welding one edge joining portion of the first composite component to one edge joining portion of the second composite component as presented at block 920. Thus, the first composite component may be joined to the second composite component by plastic welding the thermoplastic material of the respective edge joining portions.

[0044] In some examples, plastic welding 920 includes heating an area of ​​one edge joining portion of the first composite element and / or the second composite element. The thermoplastic material of the heated area can melt to fill the gap between the edge joining portion of the first composite element and the edge joining portion of the second composite element. Thus, a weld is formed between the respective edge joining portions.

[0045] In some examples, the heating area is heated to a temperature above the melting temperature of the thermoplastic material to be melted and below the degradation temperature of the thermoplastic material to be melted. Plastic welding may include heating the area of ​​the joining edge portion of the first composite element to a temperature equal to or higher than 150° C. In some examples, the heating temperature is between 150° C. and 300° C., for example, between 200° C. and 250° C.

[0046] Plastic welding may further include supplying a filler to the welding area. Thus, the filler may be supplied between the respective edge joining portions. The filler may be heated to melt and fill a gap between the edge joining portion of the first composite element and the edge joining portion of the second composite element. The filler may include a thermoplastic material.

[0047] In some examples, plastic welding includes melting a filler to at least partially mix the molten filler with an area of ​​one edge joining portion of the first composite element and / or one edge joining portion of the second composite element in the weld zone. The thermoplastic material of the heated zone may melt and may mix with the molten filler. In some examples, the filler melts and mixes with the molten thermoplastic material of the edge joining portion of the first composite element and the molten thermoplastic material of the edge joining portion of the second composite element.

[0048] Plastic welding may include at least one of laser welding, direct heat welding, induction welding, ultrasonic welding, resistance welding, and infrared welding. These methods cause a bonding fusion process. Clamping devices may be used to position and hold the composite elements in the welding position. These clamping devices may also be used to press one of the composite elements against another.

[0049] Laser welding, direct heat welding and infrared welding are all thermal welding methods. Direct heat welding may include heating adjacent edge joining portions and pressing one of the composite elements against the other. Direct heat welding may include hot gas welding involving melting filler. Direct heat welding may also include hot plate welding, in which the composite elements are arranged on a hot plate, which melts the area of ​​the adjacent edge joining portions.

[0050] In infrared welding, edge joining portions of a first composite component and an edge joining portion of a second composite component are brought into close proximity, such as contact. An infrared source heats the edge joining portions and regions of the edge joining portions melt, thereby forming a weld between the composite components.

[0051] Laser welding involves irradiating the thermoplastic material of the edge joining portion. Laser welding may include pressing one of the composite components against the other and then moving the laser beam along the weld line. A diode laser is one type of laser that can be used to laser weld two thermoplastic materials.

[0052] In resistance welding, a conductive implant is inserted between the edge joining portion of a first composite element and the edge joining portion of a second composite element. Current is applied to the conductive implant to cause resistive heating. The heat directly causes the surrounding thermoplastic material to melt. Pressure may be applied to hold the first composite element and the second composite element in the welding position.

[0053] Similar to resistance welding, induction welding uses an implant to heat the thermoplastic material. In induction welding, the implant consists of an electrical conductor embedded in an electrically insulating material. An induction coil is energized to generate an electromagnetic field that acts on the electrical conductor. The electrical conductor is then heated, and the heat is applied to the thermoplastic material.

[0054] In ultrasonic welding, high frequency amplitude vibrations are used to generate heat by friction between the edge joining portion of the first composite element and the edge joining portion of the second composite element.The first composite element and the second composite element are held together, for example using a clamping device, and then ultrasonic vibrations are applied.

[0055] Fig. 5a schematically presents a first composite element 100 to be connected to a second composite element 200. The first composite element 100 comprises a main portion 110 and an edge connecting portion 120. The second composite element 200 of this example also comprises a main portion 210 and an edge connecting portion 220. In other examples, the first composite element and / or the second composite element may comprise a plurality of edge connecting portions. These additional edge connecting portions may be used to connect the composite element to additional composite elements.

[0056] Before joining the first composite element 100 to the second composite element 200, the composite elements 100, 200 are formed. The edge joining portions 120, 220 are attached to the corresponding main portions 110, 210. The main portion 110 and the edge joining portions 120 of the first composite element 100 may be molded and poured together. Thus, the first composite element is an integrally formed composite element. Similarly, the main portion 210 and the edge joining portions 220 of the second composite element 200 may be molded and poured together. Joining the first composite element 100 to the second composite element 200 may include forming the first composite element 100 and / or the second composite element 200. Forming one of the first composite element 100 and / or the second composite element 200 may include molding the main portions 110, 210 and the corresponding edge joining portions together. The structural integrity of the composite elements 100, 200 is thus enhanced.

[0057] The edge connecting portions 120, 220 include thermoplastic materials. In some examples, the edge connecting portions 120, 220 further include reinforcing fibers. The reinforcing fibers may be, for example, glass fibers and / or carbon fibers. The fiber types and densities of the edge connecting portions 120 of the first composite element 100 and the edge connecting portions 220 of the second composite element 200 may be different. For example, one edge connecting portion may include glass fibers and the other edge connecting portion may include carbon fibers. In other examples, the type and / or density of the edge connecting portion 120 of the first composite element 100 may be substantially the same as the type and / or density of the edge connecting portion 220 of the second composite element 200.

[0058] In some examples, the thermoplastic material of the edge joining portion 120 of the first composite element 100 is different from the thermoplastic material of the edge joining portion 220 of the second composite element 200. In some examples, both edge joining portions 120, 220 are made of the same type of thermoplastic material.

[0059] In some examples, the reinforcing fibers of the main portion 110, 210 and the edge joining portion 120, 220 of the composite element 100, 200 can be the same. In other examples, the edge joining portion 120, 220 can include different types of reinforcing fibers. In some examples, the edge joining portion 120, 220 and the main portion 110, 210 include reinforcing fibers of similar density. In other examples, the density of the reinforcing fibers in the main portion 110, 210 and the edge joining portion 120, 220 of the composite element 100, 200 can be different.

[0060] In some examples, the reinforcing fibers and / or resins of the main portion 110 of the first composite element 100 and the main portion 210 of the second composite element 200 are different. In some examples, the reinforcing fibers and / or resins of the main portion 110 of the first composite element 100 and the main portion 210 of the second composite element 200 are the same.

[0061] In some examples, the resin of the main part of the first composite element and / or the second composite element is a thermosetting resin. Thus, the main part 110 of the first composite element 100 may include a thermosetting resin, and the main part 210 of the second composite element 200 may also include a thermosetting resin.

[0062] In the example of Fig. 5a, the main parts 110, 210 of both the first composite element 100 and the second composite element 200 comprise a thermosetting resin. Therefore, the reinforcing fibers of the main parts 110, 210 are embedded in the thermosetting resin.

[0063] However, in other examples, the main portion may include a thermoplastic material. The thermoplastic material may be the same as the thermoplastic material of the edge joining portion 120, 220. For example, the main portion may include a thermoplastic resin. The thermoplastic resin may be the same as the thermoplastic resin of the edge joining portion 120, 210.

[0064] The first composite element 100 and the second composite element 200 of the figure are both blade shell parts. In other examples, the component element may be a spar cap part or a spar cap part and a blade shell part. In this example, the first composite element 100 and the second composite element 200 are formed of a laminated composite material including multiple layers of reinforcing fibers embedded in a resin (e.g., a thermoplastic resin). In other examples, the composite element may be formed of an upper laminated composite material and a lower laminated composite material and a core material arranged therebetween.

[0065] Fig. 5b schematically presents the first composite element 100 and the second composite element 200 of Fig. 5a facing corresponding edge joining portions. The edge joining portion 120 of the first composite element 100 faces the edge joining portion 220 of the second composite element 200. The composite elements are arranged in a position suitable for plastic welding.

[0066] In this example, the edge joining portions 120, 220 are substantially straight and arranged in a butt weld configuration. In other examples, the edge joining portions 120, 220 may be beveled. In these examples, the edge joining portions may be arranged in a V-shaped or U-shaped butt weld configuration. In the V-shaped or U-shaped butt weld configuration, a filler may be used to fill the space formed between the edge joining portions.

[0067] In some examples, the edge joining portions 120, 220 touch. In other examples, there may be a gap between the edge joining portions 120, 220. The gap may be less than 5 mm.

[0068] A tool may be used to move at least one of the composite elements toward another. The tool may include a clamping device to hold the composite element in place for plastic welding. In some examples, the tool may be used to press one of the composite elements toward another.

[0069] Fig. 5c schematically presents the first composite element of Fig. 5a-5b plastically welded to the second composite element of Fig. 5a-5b. A welding zone 90 is formed between the edge joining portion 120 of the first composite element 100 and the edge joining portion 220 of the second composite element 200. During plastic welding, the welding zone 90 is formed between the edge joining portion 120 of the first composite element 100 and the edge joining portion 220 of the second composite element 200. The welding zone 90 allows the thermoplastic materials of the edge joining portions 120 and 220 to be bonded.

[0070] The weld zone 90 is generated by applying heat. The heat may be applied according to any of the plastic welding methods disclosed herein. A portion of the thermoplastic material of the edge joining portion 120 of the first composite element 100 and a portion of the thermoplastic material of the edge joining portion 220 of the second composite element 200 are melted. These melted portions are then mixed to form the weld zone 90.

[0071] In some examples, during plastic welding, a filler may be supplied to the welding zone 90. The filler may be mixed with the molten zone of the edge joining portions 120 and 220.

[0072] Figures 6a and 6b are examples of first composite elements 100 according to examples of the present disclosure. Although only the first composite element is depicted in the figures, it should be noted that the second composite element may be any first composite element according to the present disclosure.

[0073] In this example, the composite element is a first composite element. However, in other examples, the composite element of the figure is a second composite element.

[0074] The first composite element 100 in these figures comprises a main part 110 attached to an edge joining part 120. In these figures, the first composite element 100 is molded together, for example in a VARTM process. The main part 110 in these figures comprises an upper surface 115 aligned with an upper surface 125 of the edge joining part 120. Similarly, the lower surface 116 of the main part 110 is aligned with the lower surface 126 of the edge joining part 120.

[0075] In these figures, the first composite element 100 includes a beveled shape. This allows butt welding to be performed in a V-shaped configuration, and the first composite element includes a first composite element outer side 107 that includes an inclined surface. The first composite element outer side 107 is defined by an outer surface 127 of the edge connecting portion 120. The outer surface 127 extends between the lower surface 126 and the upper surface 125 of the edge connecting portion 120. The outer surface 127 is inclined. This inclination forms a beveled shape. In other examples, the outer surface 127 can be substantially straight. In other examples, the outer surface 127 can include a rounded shape.

[0076] In these figures, a main part 110 and an edge joining part 120 are molded together to form a first composite element 100. After curing, the resin used during molding bonds the main part 110 to the edge joining part 120. In these examples, in addition to the resin bonding, the main part 110 is also mechanically engaged with the edge joining part 120. The main part 110 includes an engagement surface 130, and the edge joining part 120 includes an engagement surface 140. The engagement surface 130 of the main part 110 is configured to mechanically engage the engagement surface 140 of the edge joining part 120. Frictional forces are generated between the engagement surfaces 130 and 140. The attachment of the main part 110 to the edge joining part is enhanced.

[0077] In some examples, one of the engagement surfaces 130, 140 includes a plurality of protrusions, and the other of the engagement surfaces 130, 140 includes a plurality of recesses configured to receive the plurality of protrusions. The protrusions cooperate with the recesses to further enhance the connection between the main portion 110 and the edge joining portion 120. The plurality of recesses may be formed by a plurality of channels or holes.

[0078] 6a, the engagement surface 130 of the main portion 110 includes an engagement inclined surface 112. The engagement inclined surface 112 extends from a lower surface 116 to an upper surface 115. The engagement inclined surface 112 of the main portion 110 is oriented in a manner such that the upper surface 115 is shorter than the lower surface 116.

[0079] 6a, the engaging inclined surface 112 of the engaging surface 130 of the main part 110 engages the engaging inclined surface 122 of the engaging surface 140 of the edge joining part 120. The engaging inclined surfaces 112 and 122 contact to generate friction to mechanically attach the main part 110 to the edge joining part 120.

[0080] In the figure, the engaging inclined surface 122 of the edge joint portion 120 extends from the lower surface 126 to the upper surface 125. A corner 128 is formed between the upper surface 125 and the engaging inclined surface 122. The edge joint portion 120 extends a length from the outer surface 127 toward the main portion 110 to the corner 128. The length may be between 50 mm and 200 mm, for example, between 50 mm and 100 mm.

[0081] The length of the lower surface 126 of the edge joining portion 120 may be between 15% and 60% of the length of the edge joining portion 120. This increases the contact surface between the main portion 110 and the edge joining portion 120.

[0082] In this example, the engaging inclined surface 112 of the main part 110 includes a plurality of depressions. The engaging inclined surface 122 of the edge connecting part 120 includes a plurality of protrusions, which match the plurality of depressions of the engaging surface 130 of the main part 110. Therefore, the mechanical bonding force of the edge connecting part 120 and the main part 110 can be increased. In other examples, the engaging inclined surface 122 of the edge connecting part 120 includes a plurality of depressions, and the engaging inclined surface 112 of the main part 110 includes a plurality of protrusions.

[0083] Referring now to Fig. 6b, edge joining portion 120 is similar to the edge joining portion of Fig. 6a. However, the joining surface 140 of edge joining portion 120 of Fig. 6b includes lower joining inclined surface 123 and upper joining inclined surface 124. Lower joining inclined surface 123 and upper joining inclined surface 124 are joined at inner end 129. In this figure, upper joining inclined surface 124 extends to upper surface 125, and lower joining inclined surface 123 extends to lower surface 126. As with edge joining portion 120 of Fig. 6a, edge joining portion 120 of Fig. 6b includes outer surface 127 connecting upper surface 125 to lower surface 126. The outer surface 127 of edge joining portion 120 defines first composite element outer side 107.

[0084] In Fig. 6b, the lower engaging inclined surface 123 of the edge connecting portion 120 is attached to the lower engaging inclined surface 113 of the main portion 110, and the upper engaging inclined surface 124 of the edge connecting portion 120 is attached to the upper engaging inclined surface 114 of the main portion 110. The upper engaging inclined surface 114 of the main portion 110 extends between the lower engaging inclined surface 113 and the upper surface 115. The lower engaging inclined surface 113 of the main portion 110 of this figure extends between the upper engaging inclined surface 114 and the lower surface 116.

[0085] 6b, the area of ​​the edge joining portion 120 defined by the upper joining inclined surface 114 and the lower joining inclined surface 113 is surrounded by the main portion 110. Therefore, the area of ​​the edge joining portion 120 is embedded in the main portion 110.

[0086] The edge connecting portion 120 of FIG. 6 b extends a length from the outer surface 127 to the inner end 129. The length may be between 50 mm and 200 mm, for example between 50 mm and 100 mm. Between 40% and 85% of the length of the edge connecting portion 120 is embedded in the main portion 110. This enhances the connection between the main portion 110 and the edge connecting portion 120.

[0087] In this example, the upper engaging inclined surface 114 and the lower engaging inclined surface 113 of the main part 110 include a plurality of recesses. The upper engaging inclined surface 124 and the lower engaging inclined surface 123 of the edge connecting part 120 include a plurality of protrusions, which match the plurality of recesses of the engaging surface 130 of the main part 110. Therefore, the mechanical bonding force of the edge connecting part 120 and the main part 110 can be increased. In other examples, the plurality of recesses can be arranged in the upper engaging inclined surface 114 or the lower engaging inclined surface 113 of the main part 110. In other examples, the recesses can be arranged in the engaging surface 140 of one edge connecting part 120.

[0088] 7a to 7c schematically present joining a first composite element to a second composite element, comprising inserting a connector between the first composite element and the second composite element.

[0089] In these figures, the first composite element 100 and the second composite element 200 are blade shell portions, each formed from a laminate composite material. In other examples, the composite elements may be spar cap portions made from a laminate composite material.

[0090] In these figures, the connector 160 is moved in direction 190 to be inserted between the first composite element 100 and the second composite element 200. The connector 160 in these figures comprises a first side portion 161 and a second side portion 162. The first side portion 161 and the second side portion 162 comprise a thermoplastic material.

[0091] In some examples, connector 160 is made of a thermoplastic material. These types of connectors can be manufactured using extrusion or injection molding processes. In other examples, first side portion 161 and second side portion 162 are coated with a thermoplastic material.

[0092] The connector 160 of these embodiments fills the gap between the edge joining portion 120 of the first composite member 100 and the edge joining portion 220 of the second composite member 200. The connector 160 is configured to be shaped to engage the edge joining portions 120 and 220. In these examples, the first side portion 161 of the connector 160 engages the outer surface 127 of the edge joining portion 120 of the first composite member 100, and the second side portion 162 of the connector 160 engages the outer surface 227 of the edge joining portion 220 of the second composite member 200. The sealing of the joint is further improved.

[0093] In these figures, outer surface 127 of edge joining portion 120 of first composite element 100 defines first composite element outside. Outer surface 227 of edge joining portion 220 of second composite element 200 defines second composite element outside. First composite element outside faces second composite element outside.

[0094] In these examples, plastic welding the edge joining portion 120 of the first composite member 100 to the edge joining portion 220 of the second composite member 200 includes plastic welding the first side portion 161 of the connector 160 and the edge joining portion 120 of the first composite member 100, and plastic welding the second side portion 162 of the connector 160 and the edge joining portion 220 of the second composite member 200. Thus, the first side portion 161 of the connector 160 is bonded to the outer surface 127 of the edge joining portion 120 of the first composite member 100. Similarly, the second side portion 162 of the connector 160 is bonded to the outer surface 227 of the edge joining portion 220 of the second composite member 200.

[0095] In these examples, connector 160 includes a cross-section including a lower portion 163 and an upper portion 164. First side portion 161 and second side portion 162 extend outwardly from lower portion 163 to upper portion 164.

[0096] In FIG. 7 a, the outer surface 127 of the edge connecting portion 120 of the first composite element 100 and the outer surface 227 of the edge connecting portion 220 of the second composite element 200 are inclined straight surfaces. The first composite element 100 and the second composite element 200 are arranged in a V-shaped butt welding configuration. The first side portion 161 and the second side portion 162 both include inclined straight surfaces. The connector 160 of the figure includes a triangular cross-sectional shape.

[0097] In FIG. 7 b , the first composite element 100 and the second composite element 200 are arranged in a U-shaped butt weld configuration. The first side portion 161 and the second side portion 162 both comprise a circular shape. The shape is configured to match the circular shape of the outer surfaces 127 and 227 of the composite elements 100 and 200 .

[0098] The connector 160 of FIG. 7c is similar to the connector 160 of FIG. 7a. However, in FIG. 7c, the connector 160 includes a first side extension 165 and a second side extension 166. The first side extension 165 is disposed at the upper portion 164 of the connector 160 and extends outwardly from the first side portion 161. Similarly, the second side extension 166 is disposed at the upper portion 164 of the connector 160 and extends outwardly from the second side portion 162.

[0099] When inserted, the first side extension 165 engages the upper surface 125 of the edge connection portion 120 of the first composite element 100, and the second side extension 166 engages the upper surface 225 of the edge connection portion 220 of the second composite element 200. Therefore, the stability of the connector 160 can be enhanced. In some examples, the upper surfaces 125 and 225 can be stepped. The first side extension 165 and the second side extension 166 can match the steps of the upper surfaces 125 and 225, respectively.

[0100] In this figure, the first side portion 161 and the second side portion 162 include inclined straight surfaces, however, in other examples, the first side portion 161 and the second side portion 162 may be rounded, for example, as depicted in the example of FIG. 7 b .

[0101] 8a to 8c schematically present joining a first composite component to a second composite component according to examples of the present disclosure.

[0102] In these figures, the first composite element 100 includes a main part 110 and an edge connecting part 120. The main part 110 of the first composite element 100 includes an upper main part 110a and a lower main part 110b. Similarly, the edge connecting part 120 includes an upper edge connecting part 120a and a lower edge connecting part 120b. The upper edge connecting part 120a is attached to the upper main part 110a, and the lower edge connecting part 120b is attached to the lower main part 110b. According to any of the examples disclosed herein, the edge connecting parts 120a and 120b can be attached to the corresponding main parts 110a and 110b.

[0103] In these figures, the upper main portion 110a and the upper edge joining portion 120a form a laminate composite material. In addition, the lower main portion 110b and the lower edge joining portion 120b form a laminate composite material. These laminates may be according to any of the examples disclosed herein.

[0104] In these figures, the core material 180 is arranged between the upper main part 110a and the lower main part 110b. Thus, the core material 180 is arranged between two laminated composite materials. The core material 180 may be any example according to the examples disclosed herein. The first composite element 100 in these figures is a sandwich panel. The first composite element 100 may be a blade shell sandwich panel.

[0105] As with the first composite element 100, the second composite element 200 in these figures is a sandwich panel, such as a blade shell sandwich panel. The main part 210 of the second composite element 200 comprises an upper main part 210a and a lower main part 210b. In these figures, the edge joining part 220 of the second composite element 200 comprises an upper edge joining part 220a attached to the upper main part 210a and a lower edge joining part 220b attached to the lower main part 210b.

[0106] The upper laminate composite material is formed by an upper main portion 210a and an upper edge joining portion 220a. The lower laminate composite material is formed by a lower main portion 210b and a lower edge joining portion 220b. The core material 180 is arranged between the two laminate composite materials.

[0107] The core material 180 of the first composite element and / or the second composite element comprises a lightweight material, such as wood, foam or any combination thereof. The core material 180 may be a solid core, a honeycomb core or a corrugated core. The thickness of the core material 180 may be between 20 mm and 100 mm. The thickness of the upper laminate composite material and the lower laminate composite material of both the first composite element 100 and the second composite element 200 may be between 20 mm and 80 mm.

[0108] In these figures, the first composite element 100 and the second composite element 200 are positioned so that the corresponding edge connection portions 120 and 220 face each other. The first composite element 100 and the second composite element 200 in these figures are beveled to define a V-shaped butt joint welding configuration. The first composite element 100 includes a first composite element outer side 107, and the second composite element 200 includes a second composite element outer side 207. The first composite element outer side 107 and the second composite element outer side 207 extend inwardly from the lower edge connection portions 120b and 220b to the upper edge connection portions 120a and 220a. In these figures, the first composite element outer side 107 faces the second composite element outer side 207. In other examples, other welding configurations may also be suitable, such as a U-shaped butt joint welding configuration.

[0109] In these figures, the first composite element outer side 107 includes the lower edge connection portion outer side 127b and the upper edge connection portion outer surface 127a. The first composite element outer side 107 includes the core material outer side between the lower edge connection portion outer side 127b and the upper edge connection portion outer surface 127a. Similarly, the second composite element outer side 207 includes the lower edge connection portion outer side 227b, the core material outer side and the upper edge connection portion outer surface 227a.

[0110] 8b, the connector 160 is intended to be inserted between the first composite element 100 and the second composite element 200 through direction 190. The connector 160 may be inserted after the lower edge joining portion 120b of the first composite element 100 is plastically welded to the lower edge joining portion 220b of the second composite element 200.

[0111] In FIG. 8 b , the lower edge joining portion 120 b of the first composite element 100 is plastically welded to the lower edge joining portion 220 b of the second composite element 200. The lower edge joining portions 120 b and 220 b may be plastically welded according to any of the examples disclosed herein. The lower edge joining portion outer side 127 b and the lower edge joining portion outer side 227 b may be heated and bonded together. Thus, a welding area 90 is formed between the lower edge joining portion outer side 127 b and the lower edge joining portion outer side 227 b. Thus, the lower edge joining portion outer side 127 b is bonded to the lower edge joining portion outer side 227 b. A filler may be used to fill the gap between the lower edge joining portion 120 b of the first composite element 100 and the lower edge joining portion 220 b of the second composite element 200.

[0112] The V-shaped configuration of the first composite element 100 and the second composite element 200 allows access to the lower edge joining portions 120b and 220b from above. A welding tool (e.g., a laser head) can be positioned between the first composite element outer side 107 and the second composite element outer side 207. This allows plastic welding of the lower edge joining portions 120b and 220b from above.

[0113] The connector 160 fills the space formed by the first composite element outer side 107 and the second composite element outer side 207. The connector 160 of FIG. 8 b can be any example according to the examples disclosed herein. The first side portion 161 and the second side portion 162 extend outward from the lower portion 163 to the upper portion 164. At least one area of ​​the first side portion 161 and the second side portion 162 includes a thermoplastic material. The first side portion 161 of the connector 160 substantially matches the first composite element outer side 107, and the second side portion 162 of the connector 160 substantially matches the second composite element outer side 207.

[0114] In some examples, areas of the upper portion 164 of the connector also include thermoplastic material. For example, the corners between the upper portion 164 and the first side portion 161 and the corners between the upper portion 164 and the second side portion 162 may include thermoplastic material.

[0115] In the figure, the lower portion 163 is configured to be arranged on the welding area 90 formed by the lower edge joining portion 120b of the first composite member 100 and the lower edge joining portion 220b of the second composite member 200. Therefore, the connector 160 can cover the welding area 90 between the lower edge joining portion 120b and the lower edge joining portion 220b.

[0116] In Fig. 8c, a connector 160 is attached to the first composite element 100 and to the second composite element 200. The connector 160 is inserted between the outside of the first composite element and the outside of the second composite element. The first side portion 161 of the connector 160 substantially fits the outside of the first composite element, and the second side portion 162 of the connector 160 substantially fits the outside of the second composite element.

[0117] In this figure, the first side portion 161 of the connector 160 is plastically welded to the edge connection portion 120 of the first composite element 100. Plastic welding the edge connection portion 120 to the first side portion 161 of the connector 160 includes plastic welding the upper edge connection portion 120a of the first composite element 100 to the first side portion 161. The upper area of ​​the first side portion 161 and the upper area of ​​the upper edge connection portion outer surface 127a of the upper edge connection portion 120a are heated and melted. Therefore, a welding area 90 is generated between the first side portion 161 and the upper edge connection portion 120a of the first composite element 100.

[0118] In Fig. 8c, the second side portion 162 of the connector is also plastically welded to the edge connection portion 220 of the second composite member 200 by plastically welding the upper edge connection portion 220a of the second composite member 200 to the second side portion 162. The upper region of the second side portion 162 and the upper region of the upper edge connection portion outer surface 227a are heated and melted. Therefore, the connector 160 is bonded to the second composite member 200 through the welding area 90 formed between the second side portion 162 and the upper edge connection portion 220a of the second composite member 200.

[0119] Thus, the connector is welded to the first composite element 100 and to the second composite element 200. Thus, the sandwich panel can be plastic welded from above. This can allow several sandwich panels to be joined in a simple manner to form a blade shell of a wind turbine blade. The automation of blade manufacturing can also be improved. Furthermore, repair of the connection between different blade shell parts can be performed from the outside of the wind turbine blade.

[0120] Fig. 9 A wind turbine blade comprising a second composite element joined to a first composite element according to an example of the present disclosure is schematically presented.

[0121] The wind turbine blade 7 of this example comprises a plurality of composite elements. In this example, the composite elements are blade shell parts. The blade shell parts may be laminated composite structures or blade shell sandwich panels. The composite elements may be according to any of the examples disclosed herein. The composite elements of this example are connected according to any of the examples disclosed herein.

[0122] The first composite member 100 is joined to the second composite member 200. The first composite member 100 is also joined to the third composite member 300. The first composite member 100 of this example includes one edge joining portion 120 plastically welded to the second composite member 200 and another edge joining portion 120 plastically welded to the third composite member 300.

[0123] Thus, a weld zone 90 is formed between one edge joining portion 120 of the first composite member 100 and one edge joining portion 220 of the second composite member 200. In this example, the weld zone 90 between the first composite member 100 and the second composite member 200 extends in a direction substantially parallel to the length extending from the blade root end 71 to the blade tip end 72.

[0124] In this figure, the first composite member 100 is joined to the third composite member 300 via a weld formed between corresponding edge joining portions 120 and 320. The weld 90 joining the first composite member 100 to the third composite member 300 extends in a direction substantially parallel to the chord extending from the leading edge 53 to the trailing edge 54.

[0125] The third composite element 300 in these examples includes three edge joining portions: one is plastically welded to the first composite element 100, another is plastically welded to the fourth composite element 400, and the last is plastically welded to the fifth composite element 500. Thus, the third composite element 300 is joined to the first composite element, to the fourth composite element 400, and to the fifth composite element 500 along corresponding welding areas 90.

[0126] In this figure, the fourth composite element 400 is also joined to the second composite element 200 and to the sixth composite element 600 through corresponding edge joining portions. In addition, the sixth composite element 600 and the fifth composite element 500 are joined together.

[0127] In other examples, the wind turbine blade 7 may include a different number of composite elements having edge joining portions with thermoplastic material. In other examples, the shape or size of the composite elements may be different. For example, the wind turbine blade 7 may include more than two composite elements extending between the leading edge 53 and the trailing edge 54. The position of the composite elements may also vary, for example depending on the length on the wind turbine blade.

[0128] For reasons of completeness, various aspects of the disclosure are set forth in the following numbered clauses: Clause 1: A method (900) for joining a first composite element (100) and a second composite element (200) of a wind turbine blade (7), wherein each of the first composite element (100) and the second composite element (200) comprises one or more edge joining portions (120, 220) comprising a thermoplastic material, the method (900) comprising: Positioning (910) an edge joining portion (120) of the first composite member (100) to face an edge joining portion (220) of the second composite member (200); An edge joining portion (120) of a first composite member (100) is plastically welded (920) to an edge joining portion (220) of a second composite member (200).

[0129] Clause 2: The method (900) of clause 1, wherein the plastic welding (920) comprises heating a region of an edge joining portion (120, 220) of the first composite component (100) and / or the second composite component (200).

[0130] Clause 3: The method (900) of clause 2, wherein the plastic welding (920) includes supplying a filler material to the weld zone (90).

[0131] Clause 4: The method (900) of clause 3, wherein the plastic welding (920) comprises melting the filler material to at least partially mix the molten filler material in the weld zone (90) with a region of an edge joining portion (120, 220) of the first composite element (120) and / or the second composite element (220).

[0132] Clause 5: The method (900) of any of Clauses 3-4, wherein the filler comprises a thermoplastic material.

[0133] Clause 6: The method (900) of any one of clauses 1-5, wherein the plastic welding (920) comprises at least one of laser welding, direct heating welding, induction welding, ultrasonic welding, resistance welding, and infrared welding.

[0134] Clause 7: The method (900) of any of clauses 1-6, wherein positioning (910) an edge joining portion (120) of the first composite element (100) to face an edge joining portion (220) of the second composite element (200) comprises positioning the edge joining portions (120, 220) in a butt-weld configuration.

[0135] Clause 8: A method (900) according to any one of clauses 1 to 7, wherein at least one of the first composite element (100) and the second composite element (200) comprises a main portion (110, 210) attached to one or more edge connecting portions (120, 220), the main portion (110, 210) comprising reinforcing fibers and a resin.

[0136] Clause 9: The method (900) according to clause 8, wherein the reinforcing fibers and / or resins of the main parts (110, 210) of the first composite element (100) and the second composite element (200) are different.

[0137] Clause 10: The method (900) according to any of clauses 8-9, wherein the reinforcing fibers and / or resin of a major portion (110, 210) of the first composite element (100) and the second composite element (200) are the same.

[0138] Clause 11: The method (900) according to any of clauses 8-10, wherein the thermoplastic material of one or more edge joining portions (120, 220) of the first composite element (100) and the second composite element (200) are different.

[0139] Clause 12: The method (900) according to any of clauses 8-11, wherein the resin of the main part (110, 210) of the first composite element (100) and / or the second composite element (200) is a thermosetting resin.

[0140] Clause 13: A method (900) according to any of clauses 8-12, wherein the main portion (110, 210) and the one or more edge connecting portions (120, 220) include engaging surfaces (130, 140) to mechanically engage the main portion (110, 210) with the one or more edge connecting portions (120, 220).

[0141] Clause 14: The method (900) of clause 13, wherein the engagement surfaces (130, 140) include engagement inclined surfaces (112, 122, 113, 123, 114, 114).

[0142] Clause 15: The method (900) of any of clauses 13-14, wherein one of the engagement surfaces (130, 140) comprises a plurality of protrusions and the other of the engagement surfaces (130, 140) comprises a plurality of recesses configured to receive the plurality of protrusions.

[0143] Clause 16: The method (900) of any one of clauses 8-15, further comprising forming a first composite element (100) and / or a second composite element (200), wherein forming one of the first composite element (100) and / or the second composite element (200) comprises molding a main portion (110, 210) and one or more edge connecting portions (120, 220) together.

[0144] Clause 17: The method (900) of any of clauses 8-16, further comprising inserting a connector (160) between the first composite member (100) and the second composite member (200), the connector (160) comprising a first side portion (161) and a second side portion (162), at least one region of the side portions (161, 162) comprising a thermoplastic material; and Wherein plastic welding (920) an edge connection portion (120) of a first composite component (100) to an edge connection portion (220) of a second composite component (200) comprises: plastically welding a first side portion (161) of the connector (160) and an edge joining portion (120) of the first composite member (100); and The second side portion (162) of the connector (160) and an edge joining portion (220) of the second composite member (200) are plastically welded.

[0145] Clause 18: The method (900) of clause 17, wherein the main portion (110) of the first composite element (100) comprises an upper main portion (110a) and a lower main portion (110b), and wherein the one or more edge connecting portions (120) of the first composite element (100) comprises an upper edge connecting portion (120a) attached to the upper main portion (110a) and a lower edge connecting portion (120b) attached to the lower main portion (110b); and wherein the first composite element (100) comprises a core material (80) arranged between the upper main portion (110a) and the lower main portion (110b); wherein the main portion (210) of the second composite element (200) comprises an upper main portion (210a) and a lower main portion (210b); and wherein the one or more edge connecting portions (220) of the second composite element (200) comprises an upper edge connecting portion (220a) attached to the upper main portion (210a) and a lower edge connecting portion (220b) attached to the lower main portion (210b); wherein plastically welding (920) an edge connection portion (120) of the first composite element (100) to an edge connection portion (220) of the second composite element (200) comprises plastically welding a lower edge connection portion (120b) of the first composite element (100) to a lower edge connection portion (220b) of the second composite element (200); wherein the first side portion (161) of the plastic welding connector (160) and an edge connection portion (120) of the first composite member (100) include the first side portion (161) of the plastic welding connector (160) and an upper edge connection portion (120a) of the first composite member (100); and The second side portion (162) of the plastic welding connector (160) and an edge connection portion (220) of the second composite component (200) include the second side portion (162) of the plastic welding connector (160) and an upper edge connection portion (220a) of the second composite component (200).

[0146] Clause 19: A method (900) according to any of clauses 17-18, wherein the connector (160) includes a cross-section having a lower portion (163) and an upper portion (164), wherein the first side portion (161) and the second side portion (162) extend outward from the lower portion (163) to the upper portion (164).

[0147] Clause 20: A wind turbine blade (7) comprising a first composite element (100) and a second composite element (200) joined according to the method of any one of clauses 1-19.

[0148] This written description uses examples to disclose the present invention, including preferred embodiments, and also enables any person skilled in the art to practice the present invention, including making and using any device or system and performing any combined method. The patent scope of the present invention is defined by the claims, and may include other examples that occur to a person skilled in the art. If such other examples have structural elements that are not different from the written language of the claims, or if they include equivalent structural elements that are not substantially different from the written language of the claims, it is intended that such other examples are within the scope of the claims. Aspects from the various embodiments described, and other known equivalents of each such aspect, can be mixed and matched by a person skilled in the art to constitute additional embodiments and techniques according to the principles of the present application. If reference marks relating to the drawings are placed in brackets in the claims, they are used only to attempt to increase the intelligibility of the claims and should not be interpreted as limiting the scope of the claims.

Claims

1. A method (900) for joining a first composite element (100) and a second composite element (200) of a wind turbine blade (7), wherein each of the first composite element (100) and the second composite element (200) comprises one or more edge joining portions (120, 220) of a thermoplastic material, the method (900) comprising: Positioning (910) an edge connecting portion (120) of the first composite element (100) to face an edge connecting portion (220) of the second composite element (200); An edge joining portion (120) of the first composite element (100) is plastically welded (920) to an edge joining portion (220) of the second composite element (200).

2. The method (900) of claim 1, wherein plastic welding (920) comprises heating a region of an edge joining portion (120, 220) of the first composite element (100) and / or the second composite element (200).

3. The method (900) according to any one of claims 1 to 2, wherein the plastic welding (920) includes at least one of laser welding, direct heating welding, induction welding, ultrasonic welding, resistance welding and infrared welding.

4. The method (900) according to any one of claims 1 to 3, wherein positioning (910) an edge joining portion (120) of the first composite element (100) to face an edge joining portion (220) of the second composite element (200) comprises positioning the edge joining portions (120, 220) in a butt-weld configuration.

5. The method (900) according to any one of claims 1 to 4, wherein at least one of the first composite element (100) and the second composite element (200) comprises a main portion (110, 210) attached to the one or more edge connecting portions (120, 220), the main portion (110, 210) comprising reinforcing fibers and resin.

6. The method (900) according to claim 5, wherein the reinforcing fibers and / or the resins of the main parts (110, 210) of the first composite element (100) and the second composite element (200) are different.

7. The method (900) according to any one of claims 5 to 6, wherein the reinforcing fibers and / or the resin of a major portion (110, 210) of the first composite element (100) and the second composite element (200) are the same.

8. The method (900) according to any one of claims 5 to 7, wherein the resin of the main part (110, 210) of the first composite element (100) and / or the second composite element (200) is a thermosetting resin.

9. A method (900) according to any one of claims 5 to 8, wherein the main part (110, 210) and the one or more edge connecting parts (120, 220) include joining surfaces (130, 140) to mechanically join the main part (110, 210) with the one or more edge connecting parts (120, 220).

10. The method (900) of claim 9, wherein one of the engagement surfaces (130, 140) includes a plurality of protrusions and the other of the engagement surfaces (130, 140) includes a plurality of recesses configured to receive the plurality of protrusions.

11. The method (900) according to any one of claims 5 to 10, comprising forming the first composite element (100) and / or the second composite element (200), wherein forming one of the first composite element (100) and / or the second composite element (200) comprises molding the main portion (110, 210) and the one or more edge connecting portions (120, 220) together.

12. The method (900) according to any one of claims 5 to 11, comprising inserting a connector (160) between the first composite element (100) and the second composite element (200), the connector (160) comprising a first side portion (161) and a second side portion (162), at least one area of ​​the side portions (161, 162) comprising a thermoplastic material; and The step of plastically welding (920) an edge connection portion (120) of the first composite component (100) to an edge connection portion (220) of the second composite component (200) comprises: plastically welding a first side portion (161) of the connector (160) and an edge connecting portion (120) of the first composite member (100); and The second side portion (162) of the connector (160) and an edge connecting portion (220) of the second composite member (200) are plastically welded.

13. The method (900) of claim 12, wherein the main portion (110) of the first composite element (100) comprises an upper main portion (110a) and a lower main portion (110b), and wherein the one or more edge connecting portions (120) of the first composite element (100) comprises an upper edge connecting portion (120a) attached to the upper main portion (110a) and a lower edge connecting portion (120b) attached to the lower main portion (110b); and wherein the first composite element (100) comprises a core material (80) arranged between the upper main portion (110a) and the lower main portion (110b); wherein the main portion (210) of the second composite element (200) comprises an upper main portion (210a) and a lower main portion (210b); and wherein the one or more edge connecting portions (220) of the second composite element (200) comprises an upper edge connecting portion (220a) attached to the upper main portion (210a) and a lower edge connecting portion (220b) attached to the lower main portion (210b); wherein plastically welding (920) an edge connection portion (120) of the first composite element (100) to an edge connection portion (220) of the second composite element (200) comprises plastically welding a lower edge connection portion (120b) of the first composite element (100) to a lower edge connection portion (220b) of the second composite element (200); wherein plastically welding the first side portion (161) of the connector (160) and an edge connection portion (120) of the first composite element (100) comprises plastically welding the first side portion (161) of the connector (160) and an upper edge connection portion (120a) of the first composite element (100); and Wherein plastic welding the second side portion (162) of the connector (160) and an edge connecting portion (220) of the second composite element (200) includes plastic welding the second side portion (162) of the connector (160) and an upper edge connecting portion (220a) of the second composite element (200).

14. A method (900) according to any one of claims 12 to 13, wherein the connector (160) includes a cross-section having a lower portion (163) and an upper portion (164), wherein the first side portion (161) and the second side portion (162) extend outward from the lower portion (163) to the upper portion (164).

15. A wind turbine blade (7) comprising a first composite element (100) and a second composite element (200) joined according to the method of any one of claims 1 to 14.

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