Wind Turbine Rotor Blade Joining With Resistive Heating
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Solution Overview
Problem
Modern wind turbine rotor blades are manufactured using thermoset plastics that are not recyclable, cannot be post-formed or re-melted, and require complex one-shot molding processes, leading to weight and transportability issues due to their large size and low weight requirements.
Innovation Solution
A method involving resistive elements and thermoplastic or weldable thermoset resins is used to join rotor blade components, allowing for assembly on-site by applying heat to melt or soften the resin, enabling faster joining without curing epoxy resin and facilitating modular construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset plastics are used to manufacture rotor blades, then the blades achieve structural integrity and stiffness, but the blades become non-recyclable and cannot be re-melted or post-formed
Solution Approach 1:
The patent changes the material parameter from traditional thermoset plastic to thermoplastic polymer, which fundamentally alters the material's response to heat and enables recycling while maintaining structural integrity through controlled melting and re-solidification processes
Solution Approach 2:
The patent employs composite materials consisting of fiber reinforcement embedded in a thermoplastic polymer matrix, combining the high strength-to-weight ratio of fibers with the recyclability and formability of thermoplastics to achieve both structural integrity and adaptability
2Strength
If one-shot molding processes are used to manufacture rotor blades, then the blades achieve continuous structure and strength, but the manufacturing cycle time increases and transportability decreases due to large size
Solution Approach 1:
The patent divides the rotor blade into multiple separable components that can be manufactured independently and assembled later, reducing individual component size for easier transport and enabling parallel manufacturing to shorten overall production cycle time while maintaining continuous structure through proper joining
Solution Approach 2:
The patent performs preliminary manufacturing of individual blade components separately, allowing parallel production and easier transport, then assembles them using joining techniques that restore structural continuity, effectively decoupling manufacturing efficiency from final structural integrity
3Strength
If rotor blades are manufactured as single large pieces, then the blades achieve optimal structural performance, but the transportability and on-site assembly capability deteriorate
Solution Approach 1:
The patent segments the rotor blade into transportable components that can be moved to the installation site and assembled, with joining methods designed to restore structural performance while enabling modular transportation and on-site construction
Solution Approach 2:
The patent introduces joining techniques as intermediary processes that connect separate blade components, creating a continuous load path that restores structural performance while maintaining the benefits of modular transportation and on-site assembly capability
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 improves transportability and reduces cycle times, enhances mechanical performance, and allows for recyclable rotor blades with reduced weight and improved structural integrity, overcoming the limitations of traditional manufacturing processes.
Implementation Method 1
energizing the resistive element so that the resistive element applies heat to the thermoplastic or weldable thermoset resin to melt or to soften it
Data Source
AI summary
A method for producing a rotor blade of a wind turbine includes the following steps: a) providing at least two different components of the rotor blade, b) placing a resistive element between the components, c) placing a thermoplastic or weldable thermoset resin between the components, d) energizing the resistive element so that the resistive element applies heat to the thermoplastic or weldable thermoset resin to melt or to soften it, and e) joining the components together by means of the molten or softened thermoplastic or weldable thermoset resin.