Wind Turbine Blade Mould Heating System Using Ethylene Glycol
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Solution Overview
Problem
Existing moulds for wind turbine blades face inefficiencies and safety issues with water-based heating systems, including freezing, corrosion, limited temperature capabilities, and potential explosions, while alternative fluids like silicone oil can contaminate the blade production process.
Innovation Solution
A mould design incorporating a continuous layer of heat conductive material, such as aluminum or copper mesh, with a sandwich construction and using pure ethylene glycol as a heat transfer fluid, which allows for higher temperatures and safer operation without silicone contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water is used as heating fluid, then the heating system is simple and inexpensive, but the temperature is limited to 90°C and corrosion/freezing problems occur
Solution Approach 1:
The patent changes the physical-chemical parameters of the heating fluid by using ethylene glycol instead of water. This allows the system to operate at temperatures up to 130°C without the freezing and corrosion problems that limit water-based systems to 90°C, while maintaining liquid state and heat transfer capability through parameter optimization of the fluid selection.
Solution Approach 2:
The patent introduces ethylene glycol as an intermediary substance between the heat source and the mould. This mediator fluid transfers thermal energy effectively while avoiding the harmful effects of water (freezing, corrosion), enabling reliable operation at higher temperatures without direct contact between water and the mould system.
2Temperature
If pressurized water is used to achieve higher temperatures, then temperature limit is removed, but dangerous leakage or explosion can occur
Solution Approach 1:
The patent changes the fluid properties by selecting ethylene glycol, which has a higher boiling point than water. This allows the system to achieve temperatures above 90°C without requiring pressurization, thereby eliminating the safety hazards of pressurized systems while still achieving the necessary heating temperatures for blade production.
3Temperature
If silicone oil is used for heating, then higher boiler temperatures are achieved, but silicone contamination occurs inside the blade workshop
Solution Approach 1:
The patent selects ethylene glycol as an intermediary heating fluid that provides the necessary high-temperature capability without the contamination problems of silicone oil. This mediator achieves temperatures up to 130°C while remaining chemically inert to blade materials and workshop environments, avoiding silicone contamination of adhesives and paint.
4Temperature
If tubes with heating fluid are used, then heating is achieved, but thermal inefficiency and complex structure result
Solution Approach 1:
The patent merges the heating function directly into the mould structure by incorporating heating channels within the mould body itself. This integration eliminates the need for separate external heating apparatus and complex piping systems, reducing device complexity while maintaining effective heat transfer to the mould surface.
Solution Approach 2:
The patent ensures continuous heat transfer by designing the heating channels to be in direct, continuous contact with the mould structure. The heating fluid flows continuously through these channels, maintaining constant thermal coupling between the fluid and mould, which eliminates thermal inefficiencies associated with intermittent or indirect heating 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 solution enables heating up to 130°C without fluid breakdown, prevents corrosion, and ensures safe, efficient heat transfer, reducing production cycle times and maintaining blade material integrity.
Implementation Method 1
the at least one tube defining a plurality of laterally spaced heating elements, and a continuous layer of heat conductive material located in the thickness direction of the mould body between the plurality of laterally spaced heating elements and the front moulding surface
Implementation Method 2
a continuous layer of heat conductive material located in the thickness direction of the mould body between the plurality of laterally spaced heating elements and the front moulding surface and extending laterally across the space between adjacent heating elements
Data Source
AI summary
A mold for molding a wind turbine blade, the mold comprising a mold body having a front molding surface and a rear face, the mold body having at least one tube therein for conveying a heating liquid therethrough, the at least one tube defining a plurality of laterally spaced heating elements, and a continuous layer of heat conductive material located in the thickness direction of the mold body between the plurality of laterally spaced heating elements and the front molding surface and extending laterally across the space between adjacent heating elements.