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公开(公告)号：US10738759B2
公开(公告)日：2020-08-11
申请号：US15428568
申请日：2017-02-09
Applicant: General Electric Company
IPC: F03D1/06 , B29C70/52 , B29C51/26 , B33Y80/00 , B29D99/00 , B29C33/00 , B29C64/106 , B29K105/06 , B29L31/08 , B29C51/12 , B29C51/10
Abstract: The present disclosure is directed methods for manufacturing spar caps for wind turbine rotor blades. In certain embodiments, the method includes forming an outer frame of the spar cap via at least one of three-dimensional (3D) pultrusion, thermoforming, or 3D printing. As such, the outer frame has a varying cross-section that corresponds to a varying cross-section of the rotor blade along a span thereof. The method also includes arranging a plurality of structural materials (e.g. layers of pultruded plates) within the pultruded outer frame of the spar cap and infusing the structural materials and the outer frame together via a resin material so as to form the spar cap. The resulting spar cap can then be easily incorporated into conventional rotor blade manufacturing processes and/or welded or bonded to an existing rotor blade.
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公开(公告)号：US10550823B2
公开(公告)日：2020-02-04
申请号：US15232900
申请日：2016-08-10
Applicant: General Electric Company
Inventor： Aaron A. Yarbrough , Donald Joseph Kasperski , Daniel Alan Hynum , Christopher Daniel Caruso
Abstract: A method for balancing segmented rotor blades for a wind turbine may include determining a weight for each of a plurality of blade segments, wherein each blade segment extends between a first end and a second and is configured to form a common spanwise section of a segmented rotor blade between the first and second ends. The method may also include determining an initial static moment for each blade segment based on the weight of the blade segment, wherein the initial static moment of at least one of the blade segments differing from the initial static moments of the remainder of the blade segments. Additionally, the method may include adding mass to each of the blade segments to increase the initial static moment for each blade segment to a predetermined static moment, wherein the predetermined static moment is greater than each of the initial static moments of the blade segments.
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公开(公告)号：US10533533B2
公开(公告)日：2020-01-14
申请号：US14835989
申请日：2015-08-26
Applicant: General Electric Company
Abstract: The present disclosure is directed to a method of manufacturing a modular rotor blade for a wind turbine. The method includes providing a plurality of resin systems for manufacturing a plurality of blade components for the modular rotor blade. Each of the resin systems includes at least one of a thermoset material or a thermoplastic material, optionally a fiber reinforcement material, and at least one additive. Thus, the method includes determining a resin system for each of the blade components based on a location and/or function of each blade component in the rotor blade. In addition, the method includes forming each of the blade components of the rotor blade from one of the plurality of resin systems and securing each of the blade components together to form the modular rotor blade.
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公开(公告)号：US10527023B2
公开(公告)日：2020-01-07
申请号：US15428620
申请日：2017-02-09
Applicant: General Electric Company
Abstract: The present disclosure is directed methods for manufacturing spar caps for wind turbine rotor blades. In certain embodiments, the method includes forming an outer frame or tray of the spar cap via at least one of three-dimensional (3D) pultrusion, thermoforming, or 3D printing. As such, the outer frame has a varying cross-section that corresponds to a varying cross-section of the rotor blade along a span thereof. The method also includes arranging a plurality of structural materials (e.g. layers of pultruded plates) within the pultruded outer frame of the spar cap and infusing the structural materials and the outer frame together via a resin material so as to form the spar cap. The resulting spar cap can then be easily incorporated into conventional rotor blade manufacturing processes and/or welded or bonded to an existing rotor blade.
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公开(公告)号：US10519927B2
公开(公告)日：2019-12-31
申请号：US15437027
申请日：2017-02-20
Applicant: General Electric Company
Abstract: The present disclosure is directed to a shear web for a rotor blade of a wind turbine and a method of manufacturing and assembling same. The rotor blade generally includes an upper shell member having an upper spar cap configured on an internal surface thereof and a lower shell member having a lower spar cap configured on an internal surface thereof. Further, the shear web extends between the spar caps along a longitudinal length of the blade. In addition, the shear web includes first and second outer pultruded layers at least partially encompassing a core material, wherein end portions of the first and second outer pultruded layers form compressed flanges at opposing ends of the shear web.
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Patent Agency Ranking
26.发明申请公开(公告)号：US20190176445A1
公开(公告)日：2019-06-13
申请号：US16273550
申请日：2019-02-12
Applicant: General Electric Company
Abstract: In one aspect, a method for manufacturing a spar cap for a wind turbine rotor blade may generally include stacking a plurality of plates together to form a plate assembly, wherein each of the plates is formed from a fiber-reinforced composite including a plurality of fibers surrounded by a thermoplastic resin material. The method may also include positioning the plate assembly relative to a mold defining a mold surface, wherein the mold surface is shaped so as to correspond to at least one blade parameter of the wind turbine rotor blade. In addition, the method may include applying pressure to the plate assembly via the mold such that at least a portion of the plate assembly conforms to the shape of the mold surface.
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公开(公告)号：US20180238299A1
公开(公告)日：2018-08-23
申请号：US15437527
申请日：2017-02-21
Applicant: General Electric Company
CPC classification number: F03D1/0675 , B29C65/02 , B29C65/4815 , B29C65/488 , B29C65/5014 , B29C65/5057 , B29C65/526 , B29C65/527 , B29C65/7855 , B29C66/1122 , B29C66/1142 , B29C66/43 , B29C66/54 , B29C66/543 , B29C66/721 , B29C66/7212 , B29C66/72141 , B29C66/73921 , B29L2031/085 , F05B2230/232 , F05B2280/4007 , Y02E10/721 , Y02P70/523 , B29K2307/04 , B29K2309/04 , B29K2305/00 , B29K2309/02 , B29K2301/00
Abstract: The present disclosure is directed to methods for joining rotor blade components using thermoplastic welding. The method includes arranging a first thermoplastic component and a second thermoplastic component together at an interface, determining a size of a tolerance gap between the first and second components at the interface, placing a thermoplastic insert between the first and second components at the interface, the insert being larger than the tolerance gap, heating the insert and the first and second components such that the insert begins to flow so as to fill the tolerance gap between the first and second components, applying pressure to the interface such that the insert and the first and second blade components remain substantially in direct contact with each other at the interface, and welding the insert and the first and second components together at the interface, wherein the heat and the applied pressure between the insert and the first and second components at the interface maintain the insert and the first and second substantially in direct contact at the interface during welding.
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公开(公告)号：US09981433B2
公开(公告)日：2018-05-29
申请号：US14862191
申请日：2015-09-23
Applicant: General Electric Company
CPC classification number: B29C73/10 , B29C33/306 , B29C33/3892 , B29C33/40 , B29C33/42 , B29C33/74 , B29C65/08 , B29C73/12 , B29C2033/0094 , B29K2105/06 , B29K2901/12 , B29L2031/085 , Y02P70/523
Abstract: The present disclosure is directed methods for modifying molds of rotor blades of a wind turbine. In certain embodiments, the blade mold is constructed, at least in part, of a thermoplastic material optionally reinforced with a fiber material. In one embodiment, the method includes identifying at least one blade mold addition for the mold of the rotor blade and positioning the blade mold addition at a predetermined location of the mold of the rotor blade. Further, the blade mold addition is constructed, at least in part, of a thermoplastic material. Thus, the method includes applying at least one of heat, pressure, or one or more chemicals at an interface of the blade mold addition and the mold so as to join the blade mold addition to the mold. In further embodiments, the methods described herein are also directed repairing thermoplastic blade molds.
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公开(公告)号：US20170268479A1
公开(公告)日：2017-09-21
申请号：US15075303
申请日：2016-03-21
Applicant: General Electric Company
Inventor： Christopher Daniel Caruso , Aaron A. Yarbrough , Daniel Alan Hynum
CPC classification number: F03D1/0675 , B29C70/021 , B29D99/0025 , F05B2280/6003 , Y02E10/721 , Y02P70/523
Abstract: The present disclosure is directed to a method for manufacturing a thermoset component having a weldable thermoplastic interface. The method includes forming a polymerized thermoplastic component having a removable protective layer on a portion thereof. Another step includes placing a plurality of dry plies and the thermoplastic component into a mold of the thermoset component with the removable protective layer facing an outer surface of the thermoset component mold. Thus, the method further includes co-infusing the dry plies and thermoplastic component with a resin material so as to form the thermoset component having a weldable thermoplastic interface.
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公开(公告)号：US20170082088A1
公开(公告)日：2017-03-23
申请号：US14860910
申请日：2015-09-22
Applicant: General Electric Company
Inventor： Aaron A. Yarbrough , Christopher Daniel Caruso , Daniel Alan Hynum
CPC classification number: F03D1/0675 , B29L2031/085 , F05B2230/10 , F05B2230/232 , F05B2240/221 , F05B2280/4007 , Y02E10/721 , Y02P70/523
Abstract: The present disclosure is directed to thermoplastic airflow modifying elements for a rotor blade for a wind turbine and methods of assembling same. The rotor blade may be constructed from at least one of a thermoset material or a thermoplastic material. Further, the rotor blade includes a blade shell defining an outer surface. Moreover, the rotor blade includes one or more layers of thermoplastic material infused to the outer surface of the blade shell so as to define one or more attachment locations. In addition, the rotor blade includes at least one airflow modifying element constructed, at least in part, from a thermoplastic material. Thus, the airflow modifying element(s) is welded to one of the attachment locations on the outer surface of the blade shell.
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