3D Grid Rotor Blade Joints With Less Adhesive and Higher Strength

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Solution Overview

Problem

Conventional wind turbine rotor blades face challenges in joining blade components due to the need for substantial bond paste, which is expensive, heavy, and can generate excess heat, posing safety hazards. Additionally, these blades require reinforcement to withstand bending moments and other loads effectively.

Innovation Solution

The method involves printing and depositing three-dimensional grid structures using a CNC device at joint areas of the rotor blade. These grid structures are designed to bond with the blade components, allowing for reduced adhesive usage and faster curing processes, thereby enhancing bonding strength and reducing weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If substantial bond paste is used to provide structure at blade joints, then buckling resistance and structural strength are improved, but weight increases and cost increases

Engineering Contradiction:

Improvebuckling resistanceVSAvoidblade weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The blade is divided into multiple sections that can be joined together, with grid structures providing localized reinforcement at joint areas rather than requiring substantial bond paste throughout the entire blade structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining grid structures made from materials such as fiberglass, carbon fiber, or Kevlar with the blade components, creating a lightweight yet strong reinforcement system that replaces heavy bond paste

Inventive Principle:

Principle #40Composite materials

2Strength

If heavy and thick adhesive sections with fast curing adhesives are used, then bonding strength is improved, but excess heat is generated creating safety hazards

Engineering Contradiction:

Improvebonding strengthVSAvoidexcess heat

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention extracts the structural reinforcement function from the adhesive itself and places it into separate grid structures, allowing the use of thin adhesive sections that do not generate excess heat while the grid structures provide the necessary structural strength

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The grid structures serve as intermediary elements between blade components, providing mechanical reinforcement and distributing loads without requiring thick adhesive layers that would generate harmful heat during curing

Inventive Principle:

Principle #24Intermediary (Mediator)

3Weight of moving object

If grid structures are printed and deposited at joint areas, then adhesive usage is reduced and weight is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improveblade weightVSAvoidmanufacturing complexity

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The invention changes the manufacturing approach from conventional molding to additive manufacturing (3D printing) of grid structures, enabling complex geometries to be created with simple processes and reducing material waste while maintaining structural integrity

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If conventional molding processes are used without grid structures, then manufacturing process is simpler, but excessive adhesive is required increasing cost and weight

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidadhesive quantity

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The grid structures are printed and deposited at joint areas before the adhesive bonding process, preparing the surfaces in advance to require minimal adhesive for bonding while providing structural reinforcement, thereby reducing the quantity of adhesive needed

Inventive Principle:

Principle #10Preliminary action

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 reduces the amount of adhesive required, minimizes hydraulic pressure needed for joint closure, and enhances bonding strength through mechanical locking. It also allows for faster curing adhesives, reduces overall process cycle time, and provides a net weight savings.

Implementation Method 1

printing and depositing three-dimensional grid structures using a computer numeric control (CNC) device

Methodology Applied

Scientific Effect3D Printing: 3D Printing

Implementation Method 2

providing an adhesive at the first joint area and contacting at least a portion of the grid structure. Securing the first blade component and the second blade component together at the first joint area via the adhesive

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentEP3775533B1Methods for joining blade components of rotor blades using printed grid structures

Publication Date: 2025.04.23 LM WIND POWER AS

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AI summary

Methods for joining a first blade component and a second blade component of a rotor blade together includes printing and depositing, via a computer numeric control (CNC) device, at least one three-dimensional (3-D) grid structure at a first joint area of the rotor blade. The first joint area contains the first blade component interfacing with the second blade component. The method also includes providing an adhesive at the first joint area to at least partially fill the grid structure. Further, the method includes securing the first blade component and the second blade component together at the first joint area via the adhesive.