Modular Thermoplastic Blade Webs With Improved Interfacial Bonding

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Solution Overview

Problem

Conventional wind turbine blade webs using thermosetting resins face issues such as long production times, infusion defects, high manufacturing costs, and poor interfacial performance, with thermoplastic webs facing challenges in recycling and interfacial performance, and existing thermoplastic designs failing to address these issues effectively.

Innovation Solution

A modular thermoplastic web structure comprising two continuous thermosetting web flanges connected to a wind turbine blade housing, with a thermoplastic modular interlayer between them, and a manufacturing method involving surface pretreatment to enhance interfacial performance, including methods like co-infusion and bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermosetting resins and vacuum infusion processes are used to fabricate webs, then the web structure can be formed, but production time is long and infusion defects such as microcracks and poor impregnation occur

Engineering Contradiction:

Improveweb qualityVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent changes the material parameter from thermosetting resin to thermoplastic resin, which fundamentally alters the processing mechanism from vacuum infusion to heating and pressing. This parameter change eliminates infusion defects and reduces production time while maintaining web quality.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes the phase transition properties of thermoplastic resin, which becomes moldable when heated and solidifies upon cooling. This phase transition enables rapid web fabrication without the lengthy curing process required for thermosetting resins, significantly reducing production time while ensuring web quality.

Inventive Principle:

Principle #36Phase transitions

2Adaptability or versatility

If web molds are lengthened and expanded to accommodate larger wind turbine blades, then the blades can be manufactured, but investment costs increase

Engineering Contradiction:

Improveblade size accommodationVSAvoidmold investment cost

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The patent segments the web into multiple independent web modules that can be manufactured separately using standard-sized molds. These modules are then connected to form the complete web for large blades. This segmentation allows the use of smaller, less expensive molds while maintaining the capability to manufacture large blades, reducing mold investment costs while preserving adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a new dimensional approach by connecting web modules through end connections rather than requiring a single continuous mold. This dimensional change in the manufacturing approach allows standard molds to produce modules for blades of various sizes, reducing the need for expensive custom-large molds while maintaining blade size adaptability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If thermosetting webs are used, then the web structure is formed, but the webs cannot be recycled or reused

Engineering Contradiction:

Improveweb structure integrityVSAvoidrecyclability

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent changes the material parameter from thermosetting resin to thermoplastic resin, which possesses recyclability while maintaining structural integrity. Thermoplastic resin can be melted and reformed, enabling recycling and reuse of web modules without compromising the structural requirements of the wind turbine blade web.

Inventive Principle:

Principle #35Parameter changes

4Ease of repair

If full-thermoplastic webs are used, then recycling is enabled, but manufacturing difficulty increases and interfacial performance deteriorates

Engineering Contradiction:

ImproverecyclabilityVSAvoidmanufacturing difficulty

Core Design Contradiction:

Ease of repairVSEase of manufacture

Solution Approach 1:

The patent segments the web into modules with thermoplastic interlayers, which simplifies manufacturing compared to full-thermoplastic webs. The modular design allows for standardized production processes and reduces manufacturing complexity while preserving recyclability through the thermoplastic nature of the interlayers.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies surface pretreatment to the thermoplastic interlayer before connecting web modules. This preliminary action enhances the interfacial performance by improving bonding between modules, eliminating the interfacial performance deterioration issue associated with thermoplastic webs while maintaining their recyclability advantage.

Inventive Principle:

Principle #10Preliminary action

5Ease of repair

If existing thermoplastic web designs are used, then recycling is possible, but interfacial performance is poor and rapid utilization is difficult

Engineering Contradiction:

ImproverecyclabilityVSAvoidinterfacial performance

Core Design Contradiction:

Ease of repairVSReliability

Solution Approach 1:

The patent applies surface pretreatment to the thermoplastic interlayer before connecting web modules. This preliminary action significantly improves interfacial performance by enhancing bonding between modules, addressing the poor interfacial performance issue of existing thermoplastic designs while maintaining recyclability and enabling rapid utilization.

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

Enables stable production of wind turbine blade webs with reduced production costs, improved product quality, and mitigates infusion defects, ensuring reliable performance through enhanced interfacial bonding.

Implementation Method 1

compounding the thermoplastic skin layer with a core material layer to obtain a thermoplastic modular interlayer

Methodology Applied

Scientific EffectHeating and pressing: Heating

Implementation Method 2

performing surface pretreatment on the thermoplastic modular interlayer, and fixedly connecting the resultant thermoplastic modular interlayer to the two continuous thermosetting web flanges

Methodology Applied

Scientific EffectSurface pretreatment:

Implementation Method 3

laying dry reinforcing fibers between web flange molds and the thermoplastic modular interlayer, and infusing and curing to form two continuous thermosetting web flanges fixedly connected to two opposite ends of the thermoplastic modular interlayer

Methodology Applied

Scientific EffectInfusion and curing:

Data Source

PatentUS20260049594A1Modular thermoplastic web structure for wind power generation, manufacturing method therefor, and wind turbine blade

Publication Date: 2026.02.19 YUANJIAN WIND POWER JIANGYINENVISION ENERGY CO LTD

AI summary

The present disclosure relates to a modular thermoplastic web structure for wind power generation, a manufacturing method therefor, and a wind turbine blade. The modular thermoplastic web structure includes: two continuous thermosetting web flanges fixedly connectable to a wind turbine blade housing; and a thermoplastic modular interlayer, disposed between the two continuous thermosetting web flanges and having two opposite ends fixedly and respectively connected to the two continuous thermosetting web flanges.