Wind Turbine Blade Segment Welding With Thermoplastic Edge Joints
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Solution Overview
Problem
The manufacturing of large wind turbine blades is complicated by the need for larger molds and complex adhesive joints, which increase weight, require long curing times, and are prone to fatigue and corrosion, affecting structural integrity and efficiency.
Innovation Solution
The use of thermoplastic materials for edge joining portions in composite elements, allowing for plastic welding to join wind turbine blade segments, reducing complexity and increasing joint strength while enabling efficient manufacturing of longer blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive joints are used to join blade segments, then the manufacturing process becomes simpler, but the joint strength decreases and the joints are prone to fatigue and surface degradation
Solution Approach 1:
The invention changes the material parameter from thermoset to thermoplastic, enabling the use of welding processes that provide both simplicity and strength. The thermoplastic material allows for plastic welding which creates strong joints while maintaining ease of manufacture through a simplified process that avoids the complexity of adhesive preparation and curing monitoring.
Solution Approach 2:
The invention replaces the chemical bonding mechanism of adhesives with a mechanical/thermal welding process. Plastic welding uses heat and pressure to fuse the thermoplastic material, creating a mechanical bond that is stronger and more reliable than adhesive joints, while eliminating the need for complex adhesive application and curing processes.
2Strength
If metal parts are used to connect blade segments, then the structural integrity is improved, but the weight of the blade increases
Solution Approach 1:
The invention uses composite materials consisting of thermoplastic polymer matrices reinforced with fibers (glass or carbon). This composite structure provides high strength-to-weight ratio, maintaining structural integrity while significantly reducing the weight compared to traditional metal connectors. The fiber reinforcement compensates for the lower inherent strength of polymers.
Solution Approach 2:
The invention changes the material class from metal to fiber-reinforced thermoplastic composite. This parameter change achieves comparable or superior structural integrity through the synergistic combination of polymer matrix (providing toughness and delamination strength) and fiber reinforcement (providing longitudinal stiffness and strength), while dramatically reducing weight.
3Length of moving object
If larger molds are used to manufacture larger blades, then the blade size is increased, but the transporting complexity increases
Solution Approach 1:
The invention divides the blade into multiple segments that can be manufactured separately in smaller, standardized molds and then joined together using plastic welding. This segmentation allows each segment to be transported independently using standard infrastructure, avoiding the need for specialized heavy-lift equipment required for monolithic large blades.
Solution Approach 2:
The invention solves the transportation problem by changing from a single large monolithic structure to multiple smaller modular units. This dimensional change in the manufacturing approach (from one-piece to multi-piece construction) enables the use of standard transportation infrastructure while still achieving the desired large blade size through assembly of segments.
4Ease of manufacture
If adhesive joints are used to join blade parts, then the manufacturing process is simplified, but the curing time increases and inspection complexity increases
Solution Approach 1:
The invention replaces the time-consuming chemical curing process of adhesives with a faster thermal welding process. Plastic welding of thermoplastic materials can be performed rapidly using heated tools or induction heating, eliminating the extended curing times required for thermoset adhesives to achieve full strength.
Solution Approach 2:
The thermoplastic material provides self-service through its inherent ability to melt and fuse when heated, creating the joint automatically without requiring external curing agents or complex chemical reactions. The material itself performs the bonding function through phase change, eliminating the need for separate curing processes and reducing overall manufacturing time.
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
Plastic welding enhances structural integrity, reduces weight, and simplifies the manufacturing process, allowing for stronger and more durable wind turbine blades with improved maintenance and recycling capabilities.
Implementation Method 1
Each of the first and the second composite elements 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 the one edge joining portion of the first composite element to the one edge joining portion of the second composite element.
Implementation Method 2
plastic welding the one edge joining portion of the first composite element to the one edge joining portion of the second composite element
Data Source
AI summary
In a first aspect, a method for joining a first composite element and a second composite element of a wind turbine blade is provided. The method comprises positioning one edge joining portion of the first composite element to face one edge joining portion of the second composite element. In addition, the method comprises plastic welding the one edge joining portion of the first composite element to the one edge joining portion of the second composite element. In a further aspect, a wind turbine blade comprising a first composite element joined to a second composite element according to any of the methods herein disclosed is provided.