Abstract: The present disclosure is directed to a conduit assembly for securing a lightning protection cable of a wind turbine lightning protection system within an internal cavity of a wind turbine rotor blade. The conduit assembly includes one or more conduit members arranged together to define an open passageway configured to receive at least a portion of the lightning protection cable along a length thereof. Further, the conduit member(s) include one or more weldable surfaces. Thus, the weldable surface(s) are configured for securement within the internal cavity of the rotor blade to at least one of a blade segment, opposing spar caps, a shear web of the rotor blade, or any other suitable blade component. More specifically, the weldable surface(s) are constructed, at least in part, of a thermoplastic material such that the conduit members can be easily welded to one or more of the blade components as described herein.

Abstract: The present subject matter is directed to a rotor blade assembly for a wind turbine having a pultruded component at an interface of a shear web and a spar cap. More specifically, the rotor blade assembly 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. A shear web extends between the spar caps along a longitudinal length of the blade. Further, the shear web includes a first end and a second end. The first end is secured to the upper spar cap at a first interface and the second end is secured to the lower spar cap at a second interface. In addition, the shear web includes at least one pultruded component configured at either or both of the first or second interfaces between the first and second ends and the upper and lower spar caps, respectively.

Abstract: The present disclosure is directed to a modular rotor blade constructed of thermoset and/or thermoplastic materials for a wind turbine and methods of assembling same. The rotor blade includes a pre-formed main blade structure constructed, at least in part, from a thermoset material. The rotor blade also includes at least one blade segment configured with the main blade structure. The blade segment(s) is constructed, at least in part, of a thermoplastic material reinforced with at least one fiber material.

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.

Abstract: A rotor blade for a wind turbine may generally include a first blade component formed from a first fiber-reinforced composite including a first thermoplastic resin material and a second blade component configured to be coupled to the first blade component at a joint interface. The second blade component may be formed from a second fiber-reinforced composite including a second thermoplastic resin material. The second fiber-reinforced composite may include a low fiber region and a high fiber region, with the low fiber region having a fiber-weight fraction that is less than a fiber-weight fraction of the high fiber region. In addition, the first thermoplastic resin material of the first fiber-reinforced composite may be welded to the second thermoplastic resin material contained within the low fiber region of the second thermoplastic composite to form a welded joint at the joint interface between the first blade component and the second blade component.

Abstract: The present subject matter is directed to a rotor blade assembly for a wind turbine having an improved shear web configuration. The rotor blade assembly includes an upper shell member having a spar cap configured on an internal surface thereof and a lower shell member having a spar cap configured on an internal surface thereof. The shear web extends between the spar caps along a longitudinal length of the blade. Further, the shear web includes at least one pultruded component defining a hollow cross-section.

Abstract: The present disclosure is directed a method for repairing a rotor blade of a wind turbine. More specifically, in certain embodiments, the rotor blade may be constructed, at least in part, of a thermoplastic material reinforced with at least one fiber material. Thus, the method includes identifying at least one defect on the rotor blade. For example, in certain embodiments, the defect(s) as described herein may include a crack, creep, void, hole, distortion, deformation, scratch, or any other blade defect. The method also includes applying at least one of heat, pressure, and/or one or more chemicals to the defect(s) for a predetermined time period until the defect is repaired.

Abstract: The present disclosure is directed to a method of assembling a modular rotor blade of a wind turbine. The method includes identifying a main blade structure, constructed at least in part, from at least one of a thermoset or a thermoplastic material. The method also includes identifying at least one blade segment, constructed at least in part, of a thermoplastic material reinforced with at least one of glass fibers or carbon fibers. Thus, the method also includes securing the at least one blade segment to the main blade structure, e.g. via welding.

Abstract: A rotor blade for a wind turbine may generally include a first blade component formed from a first fiber-reinforced composite including a first thermoplastic resin material and a second blade component configured to be coupled to the first blade component at a joint interface. The second blade component may be formed from a second fiber-reinforced composite including a second thermoplastic resin material, wherein the second thermoplastic resin material differs from the first thermoplastic resin material. The rotor blade may also include an additional layer(s) of thermoplastic resin material positioned on or integrated into the second fiber-reinforced composite at the joint interface that differs from the second thermoplastic resin material. Moreover, the first thermoplastic resin material of the first fiber-reinforced composite may be welded to the additional layer(s) of the thermoplastic resin material to form a welded joint at the joint interface between the first and second blade components.

Abstract: Methods of manufacturing rotor blade components for a wind turbine and rotor blade components produced in accordance with such methods are disclosed. In one embodiment, the method generally includes providing a mold of the rotor blade component; coating at least a portion of an interior surface of the mold with an elastomeric material; inserting a foam material within the mold; and, removing the rotor blade component from the mold, wherein the elastomeric material forms a cover skin around at least a portion of the rotor blade component. In an alternative embodiment, the method includes providing at least one support member defining a profile for the rotor blade component on a mold surface; coating at least a portion of the support member with an elastomeric material; and, allowing the elastomeric material to cure on the mold surface so as to form the rotor blade component.

Abstract: A method for in-line processing of pre-formed pultruded products may generally include transporting a pre-formed pultruded product in a processing direction along a travel path, wherein the product includes a combination of fibers and resin and wherein the product extends lengthwise in the processing direction and defines an initial width in a widthwise direction. The method may also include roughening an outer surface of the pre-formed pultruded product as the product is being transported in the processing direction along the travel path and cutting the pre-formed pultruded product lengthwise in the processing direction to form first and second pultruded plates as the product is being transported in the processing direction along the travel path, wherein each of the first and second pultruded plates defines a width in the widthwise direction that is less than the initial width of the product.

Abstract: A rotor blade may generally include a shell forming an outer skin of the blade, with the shell defining a chordwise curvature. The rotor blade may also include a spar cap extending within the shell along a spanwise direction of the blade. The spar cap may be formed from an assembly of pre-cured laminate plates. In addition, the rotor blade may include an interior shelf positioned directly between the shell and the spar cap. The interior shelf may include an outer surface extending adjacent to the shell and an inner surface opposite the outer surface. The outer surface may define a curved profile generally corresponding to a portion of the chordwise curvature of the shell and the inner surface may define a planar surface along which the spar cap extends in a chordwise direction of the blade. The interior shelf may correspond to a pre-fabricated insert for the blade.

Abstract: The present disclosure is directed to a root assembly for a rotor blade of a wind turbine and methods of manufacturing same. The root assembly includes a blade root section having an inner sidewall surface and an outer sidewall surface separated by a radial gap, a plurality of root inserts spaced circumferentially within the radial gap, and a plurality of spacers configured between one or more of the root inserts. Further, each of the root inserts includes at least one bore hole surrounded by a pre-cured or pre-consolidated composite material. In addition, the pultruded spacers are constructed of a pre-cured or pre-consolidated composite material.

Abstract: The present disclosure is directed to a root assembly for a rotor blade of a wind turbine and methods of manufacturing same. The root assembly includes a blade root section having an inner sidewall surface and an outer sidewall surface separated by a radial gap, a plurality of root inserts spaced circumferentially within the radial gap, and a plurality of spacers configured between one or more of the root inserts. Further, each of the root inserts includes at least one bushing surrounded by a pre-cured or pre-consolidated composite material. In addition, the spacers are constructed of a pre-cured or pre-consolidated composite material.

Abstract: A spar cap for a rotor blade of a wind turbine may generally include an assembly of pre-cured laminate plates stacked on one top of the other, with the assembly including an outermost pre-cured plate, an innermost pre-cured plate positioned opposite the outermost pre-cured plate and a plurality of intermediate pre-cured plates stacked directly between the outermost and innermost pre-cured plates. The outermost pre-cured plate may be configured to be positioned adjacent to an inner surface of a body shell of the rotor blade. In addition, the outermost pre-cured plate may define a plate thickness that differs from a plate thickness defined by the innermost pre-cured plate by at least 50%.

Abstract: A pre-cured laminate plate for use within a component of a wind turbine rotor blade may generally include a plate body extending in a thickness direction between a first side and a second side and in a widthwise direction between a first end and a second end. The plate body may define a plate thickness between the first and second sides. The pre-cured laminate plate may also include a plurality of channels formed in the plate body between the first and second ends. Each channel may extend in the thickness direction between a top end that is open along the first side of the plate body and a bottom end that terminates at a location between the first and second sides of the plate body such that the plate body defines a reduced thickness between the bottom end of each channel and the second side of the plate body.

Abstract: Structural support members includes a plurality of fiber reinforcing layers positioned on top of one another, wherein a plurality of intermediate fiber reinforcing layers are disposed between a top fiber reinforcing layer and a bottom fiber reinforcing layer, and wherein at least one of said fiber reinforcing layers comprises a first areal weight, and wherein at least one of said fiber reinforcing layers comprises a second areal weight different than the first areal weight. The structural support members further include a resin infused throughout the plurality of fiber reinforcing layers.

Abstract: The present disclosure is directed to a modular rotor blade for a wind turbine and methods of assembling same. The rotor blade includes a blade root section, a blade tip section, at least one leading edge segment having a forward pressure side surface and a forward suction side surface, and at least one trailing edge segment having an aft pressure side surface and an aft suction side surface. Further, the leading edge segment and the trailing edge segment are arranged between the blade root section and the blade tip section in a generally span-wise direction. In addition, the leading edge segment and the trailing edge segment are joined at a pressure side seam and a suction side seam.

Abstract: The present disclosure is directed to a pre-formed blade root section for a modular rotor blade of a wind turbine and methods of manufacturing same. More specifically, the blade root section includes a root end portion and one or more longitudinal spar caps co-infused with the root end portion and extending in a generally span-wise direction. In addition, the root end portion includes a first end and second end, wherein the first end is configured for mounting the rotor blade to a rotor of the wind turbine.

Abstract: The present disclosure is directed to a pre-formed, continuous structural component for use in assembling a modular rotor blade for a wind turbine. Further, the structural component provides support to the modular rotor blade during operation. The pre-formed structural component includes a root portion and a body portion. The root portion is configured for mounting the structural component to a blade root section of the rotor blade. The body portion is configured to extend in a generally span-wise direction. Further, the body portion defines a predetermined cross-section having a flatback portion with a first end and a second end. In addition, the first and second ends each have a flange extending perpendicularly therefrom. Thus, each flange defines a mounting surface for one or more blade segments.