Thermoplastic Wind Turbine Blade Welded Assembly
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Solution Overview
Problem
Current wind turbine blades made from thermosetting polymer composites face challenges such as high production costs, long cycle times, and difficulties in recycling, as well as the need for on-site assembly and repair, due to their mechanical and chemical sensitivity.
Innovation Solution
The development of wind turbine blades using a thermoplastic polymer composite with a (meth)acrylic thermoplastic polymer matrix and fibrous reinforcement, which allows for reduced cycle times, easy recyclability, and the use of a weld-type interface for on-site assembly and repair, utilizing a (meth)acrylic thermoplastic polymer that can be rapidly polymerized and used in existing industrial processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermosetting polymer composite is used for wind turbine blade manufacturing, then structural strength and tensile strength are achieved, but production cycle time increases and recyclability becomes difficult
Solution Approach 1:
The patent changes the fundamental parameter of polymer type from thermosetting to thermoplastic. This parameter change enables the material to be processed at lower temperatures and shorter cycle times while maintaining structural strength through the fibrous reinforcement (glass, carbon, or natural fibers) embedded in the thermoplastic matrix.
Solution Approach 2:
The patent uses composite materials consisting of thermoplastic polymer matrix combined with fibrous reinforcement (glass fibers, carbon fibers, or natural fibers). This composite structure maintains the structural strength traditionally achieved with thermosetting polymers while enabling the production advantages of thermoplastics including shorter cycle times and recyclability.
2Strength
If thermosetting polymer composite is used for wind turbine blade manufacturing, then structural integrity is maintained, but recyclability and waste management become problematic
Solution Approach 1:
The patent changes the polymer matrix from thermosetting to thermoplastic, fundamentally altering the material's end-of-life behavior. Thermoplastic matrices can be melted and reprocessed, enabling recyclability of the composite material while maintaining structural integrity during service through the fibrous reinforcement.
Solution Approach 2:
The patent enables the recovery and recycling of composite materials by using a thermoplastic matrix that can be melted and reprocessed. This allows for the recovery of valuable fibrous reinforcement materials and reduces waste accumulation, addressing the environmental concerns associated with thermosetting composite disposal.
3Strength
If thermosetting resin is used for assembling blade parts, then strong bonding is achieved, but on-site repair and adjustment become difficult
Solution Approach 1:
The patent changes the assembly method from chemical bonding with thermosetting resin to thermal welding of thermoplastic materials. This parameter change enables on-site repair and adjustment by allowing parts to be heated, softened, repositioned, and re-welded, while maintaining bonding strength through the welding process.
Solution Approach 2:
The patent introduces dynamic adjustability to the assembly process by using thermoplastic welding. This allows for part repositioning and adjustment during assembly and enables on-site repairs by heating, softening, repositioning, and re-welding components, providing flexibility that rigid thermosetting bonding cannot offer.
4Stability of the object's composition
If thermoplastic materials with high melting points are used for wind turbine blades, then structural stability is improved, but processing complexity and sensitivity to moisture increase
Solution Approach 1:
The patent applies local quality by selecting specific thermoplastic polymers with appropriate melting points and properties for different applications. Rather than using high melting point thermoplastics that increase complexity, the patent uses thermoplastics with suitable melting points that balance structural stability during operation with ease of processing during manufacturing.
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 solution enables the production of wind turbine blades with improved mechanical properties, reduced production time, and enhanced recyclability, facilitating quick and efficient on-site assembly and repair, thereby lowering production and installation costs.
Implementation Method 1
a (meth)acrylic thermoplastic polymer matrix in which the (meth)acrylic thermoplastic polymer has been rapidly polymerized
Implementation Method 2
at least one panel of thermoplastic polymer composite is connected to the stiffening member by a weld-type interface
Data Source
AI summary
The invention relates to a wind turbine blade (1) comprising an outer casing formed at least in part of panels (3) of thermoplastic polymer composite, defining a leading edge (4) and a trailing edge (5) of the wind turbine blade, and at least one longitudinal stiffening member (6) made of polymer composite, extending along a longitudinal axis (A) of the wind turbine blade inside said wind turbine blade (1), said stiffening member (6) being arranged between at least one panel defining the leading edge (4) and at least one panel defining the trailing edge (5), characterized in that the thermoplastic polymer composite comprises a fibrous reinforcement and a (meth)acrylic thermoplastic polymer matrix and in that at least one panel (3) of thermoplastic polymer composite is connected to the stiffening member (6) by a weld-type interface (7).