Wind Turbine Spar Cap Bonding with Heat-Activated Silane Primer
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Solution Overview
Problem
Existing methods for bonding wind turbine blade components, particularly the spar cap to the shell, face challenges such as reduced adhesion strength due to moisture sensitivity of isocyanate-based primers, high flammability, and health hazards from dust and noise, necessitating improved and safer bonding processes.
Innovation Solution
A method involving the use of a silane-containing primer composition applied to the spar cap surface, followed by heat activation and co-infusion with resin, forming strong bonds without the need for surface grinding, resulting in up to five times higher bond strength and improved fracture toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional adhesive bonding procedures are used on GFRP and NFRP substrates, then the bonding process is simple, but the adhesive bonding strength is insufficient and delamination occurs under fatigue loading
Solution Approach 1:
The patent applies preliminary action by performing plasma treatment on the GFRP and NFRP substrates before adhesive bonding. This pre-treatment modifies the surface properties of the substrates to enhance adhesion, preventing delamination under fatigue loading while maintaining a relatively simple overall process
Solution Approach 2:
The patent changes the physical and chemical parameters of the substrate surfaces through plasma treatment. The treatment alters surface energy, roughness, and chemical composition, creating optimal conditions for adhesive bonding and significantly improving bonding strength without requiring complex bonding procedures
2Reliability
If conventional adhesive bonding is used without surface treatment, then the bonding process is fast, but the adhesive bond fails under moisture and fatigue conditions
Solution Approach 1:
Plasma treatment is applied as a preliminary step to prepare the substrate surfaces. This treatment creates a more reliable adhesive bond by modifying surface properties, and the relatively short plasma treatment duration minimizes time loss compared to conventional surface preparation methods
Solution Approach 2:
The patent replaces mechanical surface preparation methods (such as sanding or grinding) with plasma treatment. This substitution provides more reliable surface modification for adhesive bonding while requiring less time and producing a cleaner, more consistent surface
3Strength
If plasma treatment is applied to GFRP and NFRP substrates, then adhesive bonding strength improves significantly, but the process complexity increases
Solution Approach 1:
The patent replaces complex mechanical surface preparation procedures with plasma treatment. This substitution achieves superior adhesive bonding strength while simplifying the manufacturing process, as plasma treatment can be applied automatically and requires less manual intervention than traditional mechanical methods
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
The method provides a safer, more efficient, and environmentally friendly bonding process with enhanced adhesion between the spar cap and shell, reducing costs and environmental impact while maintaining structural integrity.
Implementation Method 1
A method for improving the adhesive bonding of wind turbine blade components is provided. The method comprises the steps of: a) providing a blade component comprising a first substrate and a second substrate, wherein at least one of the first substrate and the second substrate is made of glass fibre reinforced plastic (GFRP) or natural fibre reinforced plastic (NFRP); b) treating at least one of the first substrate and the second substrate with plasma; c) applying an adhesive to at least one of the first substrate and the second substrate; and d) joining the first substrate and the second substrate using the adhesive.
Data Source
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AI summary
A method is provided of manufacturing a wind turbine blade shell member (36, 38), the method comprising the steps of providing a blade mould (96) for the blade shell member, arranging one or more layers of fibre material in the moulding cavity to provide a fibre layup (97), and providing a pre-manufactured spar cap member (62). The surface of the spar cap member is treated with a primer composition to provide a primer-treated surface. Heat is then applied to the primer-treated surface of the spar cap member to provide an activated surface, for improving the bonding in a subsequent resin co-infusion of the spar cap member and the fibre layup.