Wind Turbine Blade Spar Segment Jointing via Simultaneous Curing
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Solution Overview
Problem
The connection of spar segments in wind turbine blades is challenging due to non-uniform adhesive distribution, which affects the structural integrity and manufacturing efficiency, especially for large blades where high shear and tension forces are prevalent.
Innovation Solution
A method involving overlapping adhering portions of spar segments with an adhesive and simultaneously curing the adhesive and resin-impregnated fiber layers to create a strong and durable joint, optimizing the connection and reducing manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spar segments are connected using adhesive alone, then the manufacturing process is simple, but the adhesion strength is insufficient under high shear and tension forces
Solution Approach 1:
The patent combines adhesive bonding with fiber layers impregnated with resin to create a composite connection system. The fiber layers (e.g., carbon fiber or glass fiber reinforced plastic) are positioned between the spar segments and cured simultaneously with the adhesive, forming a composite structure that provides both chemical bonding and mechanical reinforcement, thereby significantly enhancing the connection strength under operational loads.
Solution Approach 2:
The patent employs simultaneous curing of the adhesive and the resin in the fiber layers by controlling curing parameters such as temperature and time. This parameter control ensures that both materials reach optimal curing conditions together, maximizing the bond strength and structural integrity of the joint while maintaining manufacturing efficiency.
2Ease of manufacture
If adhesive is applied between overlapping spar segments, then the segments are connected, but the adhesive distribution is non-uniform affecting structural integrity
Solution Approach 1:
The fiber layers impregnated with resin serve as an intermediary material between the spar segments and the adhesive. These pre-positioned fiber layers provide a uniform substrate that promotes even adhesive distribution across the bonding surface, ensuring consistent structural integrity throughout the joint region.
Solution Approach 2:
The patent controls the curing parameters (temperature, time, pressure) to ensure uniform curing of both the adhesive and the resin-impregnated fiber layers. This parameter control prevents non-uniform adhesive distribution and ensures consistent bond quality across the entire joint area.
3Ease of manufacture
If adhesive and resin are cured separately, then each material can be optimized independently, but the manufacturing time increases
Solution Approach 1:
The patent merges the curing processes of the adhesive and the resin-impregnated fiber layers into a single simultaneous curing operation. By positioning the fiber layers between the spar segments before adhesive application and then curing both materials together under controlled conditions, the patent eliminates sequential curing steps, significantly reducing manufacturing time while maintaining optimal curing for both materials.
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 strong, long-lasting adhesion between spar segments, enhancing the structural integrity to withstand operational loads while shortening the manufacturing process by curing the adhesive and resin simultaneously.
Implementation Method 1
an adhesive is at least partially provided between the overlapping adhering portions
Implementation Method 2
providing at least one fiber layer impregnated with an uncured resin on the outer surfaces of the first and second spar segments
Implementation Method 3
simultaneously curing the adhesive and the resin, thereby fixating the first and the second spar segments to each other
Data Source
Figure 1~3
Figure 4
AI summary
A method for manufacturing a blade spar for a wind turbine blade, comprising the steps of: positioning (17) a first spar segment (2) having a first adhering portion (8); positioning (18) a second spar segment (3) having a second adhering portion (9) at the first spar segment (2), such that the first adhering portion (8) and the second adhering portion (9) are at least partially overlapping, wherein an adhesive is at least partially provided between the overlapping adhering portions (8, 9); providing (22) at least one fiber layer (13) impregnated with an uncured resin on the outer surfaces of the first and second spar segments (2, 3) at least in the joint region (11) of the first and second spar segments (2, 3); and simultaneously curing (23) the adhesive (10) and the resin, thereby fixating the first and the second spar segments (2, 3) to each other.