Wind Turbine Blade Thermal Welding for Lightning Flashover Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for connecting wind turbine blade components, such as adhesive processes and infusion of resin, are time-consuming and add significant weight, while thermal welding lacks effective integration into lightning protection systems.

Innovation Solution

The wind turbine blade components are connected via thermal welding with a resistive element between them, which is integrated into the lightning protection system, using a surge protection device to manage voltage differences and prevent flashovers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive processes or resin infusion are used to connect blade components, then the connection is reliable, but the manufacturing time is extended and significant weight is added

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces chemical bonding processes (adhesive curing or resin infusion) with thermal welding using a resistive element. This substitution eliminates the need for curing time while maintaining connection reliability, directly resolving the time-consuming nature of chemical bonding methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the connection method from chemical processes to thermal processes by applying controlled heat through the resistive element. This parameter change (from chemical to thermal) enables faster manufacturing without compromising joint strength, addressing the time-loss issue.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If adhesive processes or resin infusion are used to connect blade components, then the connection is reliable, but the blade weight increases significantly

Engineering Contradiction:

Improveconnection reliabilityVSAvoidblade weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent substitutes chemical bonding materials (adhesives or resin) with a thermal welding process using a resistive element. This elimination of additional bonding materials directly reduces blade weight while preserving connection reliability through direct thermal bonding of the base materials.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention extracts and eliminates the need for separate adhesive or resin materials by integrating the heating function directly into the connection process through the resistive element. This removal of extra materials achieves weight reduction while maintaining reliable connections.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If thermal welding is used to connect blade components, then manufacturing time is reduced and weight is saved, but the resistive element creates flashover risks during lightning strikes

Engineering Contradiction:

Improvemanufacturing speedVSAvoidlightning flashover risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a surge protection device as an intermediary between the resistive element and the blade structure. This mediator prevents direct electrical discharge paths during lightning strikes, eliminating flashover risks while preserving the benefits of thermal welding for rapid manufacturing.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention implements protective measures (surge protection device and insulation) beforehand to cushion against potential lightning damage. This preemptive protection allows the use of thermal welding methods without introducing harmful flashover risks, resolving the contradiction between manufacturing efficiency and safety.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 method provides a faster connection process without added weight, integrates the resistive element into lightning protection, and prevents uncontrolled current flows during lightning strikes.

Implementation Method 1

a resistive element arranged between the first and second blade components in the overlap region as a remnant of the thermal welding

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a lightning conductor electrically connected with each of the first and second terminals

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS12595782B2Wind turbine blade and method for manufacturing a wind turbine blade

Publication Date: 2026.04.07 GAMESA INNOVATION & TECH SL

AI summary

A wind turbine blade is provided, including: a first and a second blade component connected with each other in an overlap region by thermal welding, a resistive element arranged between the first and second blade components in the overlap region as a remnant of the thermal welding, the resistive element having a first and a second terminal, a lightning conductor electrically connected with each of the first and second terminals, and a surge protection device, wherein one of the first and second terminals is electrically connected with the lightning conductor via the surge protection device. The resistive element which was used for the welding process and is left in the blade as a remnant of the welding process can be integrated into the lightning protection system of the blade.