Thermal Welding Wind Turbine Blade Joints
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Solution Overview
Problem
Traditional wind turbine blade manufacturing using adhesives is time-consuming and expensive, with adhesive joints prone to cracking and debonding due to static and cyclic fatigue loads, and high manufacturing tolerances, leading to structural collapse and increased costs.
Innovation Solution
The use of thermoplastic resin components and thermal welding techniques, including resistance and induction welding, to create stable and durable joints by melting brackets infused with carbon fiber into the shear web and spar caps, eliminating the need for adhesive bonds and reducing manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive bonds are used to join wind turbine blade components, then the manufacturing process is simpler and more traditional, but the joints are prone to cracking and debonding due to static and cyclic fatigue loads, leading to reduced reliability
Solution Approach 1:
The patent changes the bonding mechanism from chemical adhesion to thermal fusion by heating the thermoplastic resin components to their melting point, allowing the flanges to fuse directly to the spar caps and shear web. This parameter change (from room temperature adhesive bonding to elevated temperature thermal welding) eliminates the fatigue susceptibility of adhesive joints while maintaining manufacturing feasibility through controlled heating processes
Solution Approach 2:
The patent replaces the chemical bonding system (adhesives) with a thermal-mechanical bonding system (thermal welding). The heating elements apply thermal energy to melt the thermoplastic resin, and the mechanical pressure system applies force to ensure intimate contact and fusion. This substitution creates joints that are inherently more resistant to fatigue loads while the process remains manufacturable through integrated tooling
2Ease of manufacture
If adhesive joints with thickness ranging from 5 mm to 20 mm are used, then the manufacturing process allows for material property variation, but the increased adhesive thickness leads to higher costs and potential structural weaknesses
Solution Approach 1:
The patent changes the bond line thickness parameter from millimeter-scale adhesive layers to sub-millimeter thermoplastic resin interfaces. The heating process melts the thermoplastic material, allowing it to flow and create intimate contact across the joint interface. This parameter reduction (from 5-20 mm adhesive thickness to much thinner fused interfaces) eliminates the weaknesses associated with thick adhesive layers while maintaining manufacturing flexibility through the thermoplastic material's inherent properties
Solution Approach 2:
The patent utilizes thermoplastic resin composite materials that combine the structural reinforcement of carbon fiber or glass fiber with the bonding capability of thermoplastic matrices. These composite flanges and shear web components provide both structural integrity and bonding functionality in a single integrated material system, eliminating the need for separate thick adhesive layers and reducing overall joint thickness while improving reliability
3Productivity
If traditional adhesive manufacturing processes are used, then the process is well-established, but the manufacturing time is excessive and costs are high
Solution Approach 1:
The patent replaces the time-consuming adhesive curing process with rapid thermal welding. The heating elements directly heat the thermoplastic resin components to melting temperature, and the material fuses quickly under applied pressure. This substitution eliminates the extended curing times required for adhesive bonds while the integrated heating and pressure application systems maintain ease of manufacture through conventional manufacturing techniques
Solution Approach 2:
The patent changes the temperature parameter during the bonding process from ambient (adhesive application) to elevated (thermal welding). By heating the thermoplastic resin to its melting point and maintaining it there briefly for fusion, then cooling under pressure, the process achieves rapid bonding without the extended curing times of adhesives. This parameter change accelerates manufacturing while the controlled thermal profile keeps the process manageable and manufacturable
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 results in stronger, more reliable wind turbine blades with reduced manufacturing time and costs, as well as improved resistance to fatigue loads, by forming cohesive bonds that are more stable and durable than traditional adhesive joints.
Implementation Method 1
a plurality of heating elements positioned within the first bond, the second bond, the third bond, and the fourth bond... activating the plurality of heating elements
Implementation Method 2
The plurality of heating elements is magnetically susceptible... using a coil to produce a magnetic field which stimulates the plurality of heating elements
Implementation Method 3
a pressure is applied to both the third end and the fourth end... applying a pressure to the first bond, the second bond, the third bond, and the fourth bond
Implementation Method 4
The first spar cap, the shear web, and the first flange are comprised of a thermoplastic resin... creating a first bond, with the first heating element contained within the first bond
Data Source
AI summary
Disclosed herein are methods, devices, and systems for manufacturing wind turbine blades which in some instances require using new blade joint designs. The blade joint designs described herein may allow for contact in places where welds will be made, which allows for existing manufacturing tolerances to be used while still enabling the use of thermal welding for wind turbine blades.