Wetted Composite Bonding for Wind Turbine Rotor Blades
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Solution Overview
Problem
Conventional adhesive bonding in wind turbine rotor blades results in excessive weight, bond strength issues, and costly repairs due to excess bond paste and air voids, particularly at critical junctures like the shear web and spar cap interfaces.
Innovation Solution
A method involving the use of wetted composite materials, such as fiber-reinforced resin layers, is applied between composite blade components to form a cured bond, replacing conventional bond paste and allowing for improved bonding without excess material, using techniques like hand-lay up or automatic unrolling of fiber materials through a resin bath.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bond paste is used to bond shear web and spar cap, then bond width can be achieved, but excessive weight is added and bond strength is reduced due to excess paste and air voids
Solution Approach 1:
The patent changes the material parameters by transitioning from conventional bond paste to a fiber-reinforced composite material system. The fiber mat (e.g., glass fiber, carbon fiber) embedded in resin replaces the paste-like adhesive, fundamentally altering the bonding material's mechanical properties, weight characteristics, and structural functionality to achieve both high bond strength and reduced weight.
Solution Approach 2:
The invention employs composite materials consisting of fiber reinforcement (glass fiber, carbon fiber, or other fibers) combined with resin matrix. This composite approach replaces conventional bond paste with a material that provides both adhesive bonding and structural reinforcement, eliminating the need for excess material while improving bond strength and reducing weight through the high strength-to-weight ratio of fibers.
2Reliability
If excess bond paste is applied to achieve desired bond width, then bond coverage is improved, but material cost increases and repair complexity increases
Solution Approach 1:
The patent changes the material form from paste to a fiber mat reinforced composite system. The fiber mat provides self-contained reinforcement that distributes stress evenly across the bond line, ensuring reliable coverage without requiring excess material application. This structured approach simplifies the bonding process and reduces repair complexity compared to managing excess paste.
3Strength
If conventional bond paste is used at critical junctures, then bonding can be achieved, but air voids and unpredictable squeeze-out result in decreased bond strength
Solution Approach 1:
The fiber-reinforced composite material provides structured reinforcement that maintains consistent material distribution across the bond interface. The fiber mat structure prevents air void formation by providing a continuous reinforcement network, and the resin-impregnated fibers ensure uniform material placement without unpredictable squeeze-out, achieving consistent bond strength at critical junctures.
4Weight of moving object
If fiber-reinforced composite material is used instead of bond paste, then weight is reduced and bond strength is enhanced, but material application process becomes more complex
Solution Approach 1:
The fiber mat is pre-impregnated with resin in a controlled manufacturing process before application to the blade. This preliminary impregnation ensures uniform resin distribution and proper fiber saturation, simplifying the actual bonding operation. The pre-prepared fiber mat can be directly placed and consolidated in the mold, reducing on-site manufacturing complexity while achieving the weight and strength benefits.
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 reduces weight, enhances bond strength, and lowers costs by providing a durable, reinforced interface compatible with existing resin systems and manufacturing processes, suitable for various blade components including shear webs and spar caps.
Implementation Method 1
drawing a fiber material through a bath of resin material, placing the wetted fiber material at the interface
Implementation Method 2
placing one or more layers of the wetted composite material between the first and second blade components
Implementation Method 3
allowing the one or more layers of the wetted composite material at the interface to cure
Data Source
AI summary
The present disclosure is directed to a method for bonding composite blade components of a rotor blade of a wind turbine. The method includes providing a first blade component being constructed of a first composite material. The method also includes providing a second blade component being constructed of a second composite material. Further, the method includes arranging the first and second blade components together at an interface. Another step includes placing one or more layers of a wetted composite material between the first and second blade components at the interface. The method also includes allowing the one or more layers of the wetted composite material at the interface to cure.