Wind Turbine Blade Root Metal Insert Adhesion
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Solution Overview
Problem
The existing methods for manufacturing wind turbine blades, particularly those using the infusion process, face challenges in achieving strong adhesion between metal inserts and the blade root, leading to potential mechanical weaknesses and increased costs due to the use of lower strength resins and less efficient fibre alignment.
Innovation Solution
The method involves manufacturing impregnated metal inserts with a prepreg layer, which are then embedded within the blade root using an infusion technique, ensuring high viscosity resin bonding for enhanced mechanical properties and cost-effectiveness, allowing for easier handling and integration with other fibre layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the infusion process is used to manufacture blade roots, then production costs are reduced, but adhesion between metal inserts and blade root deteriorates
Solution Approach 1:
The metal inserts are pre-impregnated with resin and cured before being embedded in the blade root during infusion. This preliminary action ensures strong adhesion is already present on the insert surface, resolving the adhesion problem while maintaining infusion cost benefits
Solution Approach 2:
The patent changes the physical-chemical state of the insert by pre-applying resin and curing it at elevated temperatures (80-120°C) before infusion. This parameter change creates a pre-bonded surface that overcomes the poor adhesion issue of standard infusion processes
2Strength
If prepreg process is used to manufacture blades, then fibre alignment and mechanical properties are improved, but production cost increases
Solution Approach 1:
The patent applies prepreg technology locally only to the metal inserts rather than the entire blade. This localized application provides high mechanical properties where needed (at the critical blade root connection) while maintaining cost-effectiveness for the rest of the blade structure
Solution Approach 2:
The manufacturing process is segmented into two parts: inserts are made with prepreg for high strength, while the main blade structure uses cheaper infusion. This segmentation allows optimization of each component according to its specific requirements
3Reliability
If metal inserts are made longer to increase adhesion surface, then adhesion between inserts and blade root is improved, but device complexity and material usage increase
Solution Approach 1:
Instead of changing the geometric parameter of insert length, the patent changes the chemical parameter by pre-applying resin to the insert surface. This creates strong adhesion without requiring increased insert length or design complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in wind turbine blades with improved mechanical properties and reduced production costs, as the prepreg layer provides strong adhesion between metal inserts and composite materials, facilitating the use of lower viscosity resins and simpler storage conditions.
Implementation Method 1
heating for curing such that a resin impregnated fibre layer adheres to the outer surface of the insert
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
Method of manufacturing an impregnated metal insert for a wind turbine blade root, the insert comprising an outer surface and an open end adapted to receive a fastening element for attachment to a wind turbine rotor hub, wherein the method comprises covering the insert outer surface with one or more resin pre impregnated fibre layers, and heating for curing such that a resin impregnated fibre layer adheres to the outer surface of the insert. The disclosure is further related to the method of manufacturing a portion of a wind turbine blade.