Wind Turbine Blade Mold With Copper Wire Thermal Conductors
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Solution Overview
Problem
Conventional wind turbine blade molds with fluid conduits for heating/cooling face challenges such as non-uniform heat distribution, local heat maxima causing structural issues, corrosion, limited temperature range, and complex equipment, which affect the quality and homogeneity of composite materials.
Innovation Solution
A mold with thermal conductors, such as metal foil or copper wires, integrated within the flange portions to transfer heat efficiently and uniformly, eliminating the need for fluid conduits and allowing for controlled heating/cooling without the drawbacks of conventional systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fluid conduits are used for heating/cooling in conventional molds, then heating/cooling function is provided, but non-uniform heat distribution and local heat maxima occur
Solution Approach 1:
The patent replaces the mechanical fluid conduit system with an electromagnetic heating system. A heating element (electromagnetic source) is positioned adjacent to the mold, and electromagnetic energy is coupled through a coupling element directly to the composite material, eliminating the need for fluid circulation systems and achieving more uniform heat distribution without local maxima
Solution Approach 2:
The patent introduces a coupling element as an intermediary between the heating element and the composite material. This coupling element facilitates efficient electromagnetic energy transfer while maintaining uniform heat distribution across the material, solving the heat uniformity problem without requiring complex fluid conduit networks
2Reliability
If fluid conduits are used for heating/cooling, then temperature control is achieved, but corrosion occurs
Solution Approach 1:
The patent eliminates the fluid conduit system entirely by using electromagnetic heating. The heating element and coupling element create heat through electromagnetic energy conversion, requiring no fluid circulation, thus completely preventing corrosion issues associated with fluid-based systems while maintaining reliable temperature control
3Ease of operation
If fluid conduits are used, then heating function is provided, but the system becomes complex
Solution Approach 1:
The patent replaces the complex network of fluid conduits, pumps, and fluid circulation equipment with a simpler electromagnetic heating system. The heating element and coupling element provide all necessary heating functionality without requiring fluid storage tanks, pumps, valves, or circulation piping, dramatically reducing system complexity
Solution Approach 2:
The patent extracts and removes the fluid conduit system from the mold design, keeping only the essential heating functionality. By eliminating the fluid circulation infrastructure, the system becomes significantly simpler while maintaining effective temperature control capabilities
4Productivity
If conventional heating systems are used, then heating is provided, but cycle time is extended
Solution Approach 1:
The patent replaces slow thermal conduction through fluid conduits with rapid electromagnetic heating. The electromagnetic energy couples directly to the composite material through the coupling element, heating the material much faster than fluid-based systems can achieve, thereby reducing both heating duration and overall cycle time
Solution Approach 2:
The patent employs periodic or pulsed electromagnetic heating through the heating element. By delivering energy in controlled pulses or cycles, the system achieves rapid and uniform heating of the composite material, significantly reducing the time required compared to continuous slow heating from fluid conduits
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 mold provides consistent and controlled heat transfer, reducing cycle time, minimizing internal stresses and warpage, and enhancing the quality of composite materials by ensuring uniform curing and avoiding corrosion-related issues.
Implementation Method 1
a thermal conductor disposed within at least a portion of the second flange portion... the thermal conductor is configured to transfer heat through the first flange portion and second flange portion
Data Source
AI summary
A mold for forming a flange of a wind turbine blade comprising a first flange portion including a plurality of lamina and having a generally planar shape and a second perpendicular flange including a plurality of lamina. A plurality of copper wires are disposed within the lamina for conducting heat delivered from a base portion through the first and second flange portions. The mold is free of fluid conduits with the flange portions moveable relative to the base portion.