Abstract: A rotor blade assembly includes a rotor blade defining a pressure side and a suction side extending between a leading edge and a trailing edge. Further, the rotor blade assembly includes at least one structural feature secured within the rotor blade and spaced apart from the trailing edge to define a void between the pressure side, the suction side, and the trailing edge. Moreover, the rotor blade assembly includes an adhesive filling the void between the pressure side, the suction side, and the trailing edge to provide an adhesive connection between the pressure side, the suction side, the trailing edge, and the structural feature(s). In addition, the adhesive contacts the structural feature(s) at an interface and defines a fillet profile.

Abstract: The present disclosure is directed to an apparatus for manufacturing a composite component. The apparatus includes a mold onto which the composite component is formed. The mold is disposed within a grid defined by a first axis and a second axis. The apparatus further includes a first frame assembly disposed above the mold, and a plurality of printheads coupled to the first frame assembly within the grid in an adjacent arrangement along the first axis. At least one of the mold or the plurality of printheads is moveable along the first axis, the second axis, or both. At least one of the printheads of the plurality of printheads is moveable independently of one another along a third axis.

Abstract: In an aspect, the present disclosure is directed to a composite structure. The composite structure includes a three-dimensional (3-D) grid structure and at least one monolithic skin layer at least partially enveloping and securing the grid structure. As such, the grid structure is configured to stabilize the composite structure under at least one of: static local buckling and dynamic global buckling.

Abstract: A method of manufacturing a wind turbine blade, comprising the steps of: placing one or more shell fibre layers on a mould surface of a blade mould, placing a plurality of separately provided preforms directly on the one or more shell fibre layers in a stacked arrangement, infusing and curing the stacked preform arrangement, the one or more shell fibre layers together via a resin in mould cavity of the blade mould to form a wind turbine blade part with a spar cap integrated in a shell part providing part of the aerodynamic shape of the wind turbine blade.

Abstract: Disclosed is a tip section for a wind turbine blade. The tip section comprises an intermediary blade section comprising a first shell part forming a first side of the intermediary blade section and a second shell part forming a second side of the intermediary blade section, the intermediary blade section having a leading edge and a trailing edge and extending from an intermediary blade section first end to an intermediary blade section second end; a tip part forming an end of the tip section and having been rigidly attached to the intermediary blade section first end, the tip part having an outer surface comprising a metal area; and a number of one or more superficial metal strips extending along an outer surface of the intermediary blade section. A wind turbine blade with such a tip section and the manufacturing of such a wind turbine blade is also disclosed.

Abstract: A sparcap for a spar structure inside a wind turbine blade is provided. A down conductor element is integrated on a side of the sparcap such that after assembly of the sparcap into the spar structure, the down conductor element extends along an outer corner of the spar structure.

Abstract: A rotor blade assembly includes a rotor blade defining a pressure side and a suction side extending between a leading edge and a trailing edge. Further, the rotor blade assembly includes at least one structural feature secured within the rotor blade and spaced apart from the trailing edge to define a void between the pressure side, the suction side, and the trailing edge. Moreover, the rotor blade assembly includes an adhesive filling the void between the pressure side, the suction side, and the trailing edge to provide an adhesive connection between the pressure side, the suction side, the trailing edge, and the structural feature(s). In addition, the adhesive contacts the structural feature(s) at an interface and defines a fillet profile.

Abstract: A segmented rotor blade for a wind turbine includes a first rotor blade segment, a second rotor blade segment, at least one thermoplastic material, and an internal pressure source. The first rotor blade segment includes a first joint end. The second rotor blade segment includes a second joint end. The first and second joint ends are arranged together in an end-to-end orientation so as to form at least one scarf joint. The at least one thermoplastic material is arranged at each of the first and second joint ends. The first and second joint ends of the first and second rotor blade segments are bonded together via thermoplastic welding of the at least one thermoplastic material. The internal pressure source provides pressure to the scarf joint during the thermoplastic welding. The internal pressure source remains within the rotor blade after thermoplastic welding is complete.

Abstract: A wind turbine blade and a method of moulding a wind turbine blade tip section. The overall wind turbine blade has an elongate structure extending in a radial sense in a finished wind turbine. The blade comprises a fairing that one is supported along its length by a spar extended along the full length of the fairing from the root end to the tip. The fairing is in two parts with a main part extending from the root for most the of the longitudinal length of the blade and the tip section forming the remainder of the blade.

Abstract: The present invention relates to a method of moulding a composite article using a mould. The mould includes first and second rigid mould parts between them defining a mould cavity. A reservoir of resin is connected to an inlet into the mould cavity. A suction pump is connected to a port on the opposite side of the mould cavity from the inlet. At least one of the mould parts has an arrangement of grooves on the surface facing the mould cavity to distribute resin across the mould cavity. The method includes laying up fibres in the mould cavity, injecting resin from the reservoir by running the suction pump to fill the mould cavity with resin, curing the resin article to form a moulded article and opening the mould and removing the article.

Abstract: A wind turbine blade comprising first and second adjacent blade sections arranged end to end along the length of the blade. Each section comprises an aerodynamic fairing and a spar. Each spar comprises a shear web extending across the fairing and a pair of spar caps, one at either end of the shear web. Each spar cap in the first section has a different cross-sectional shape and/or material from the respective spar cap in the second section and wherein the spar cap in the first section is joined to the respective spar cap in the second section via a connection piece. Each connection piece is a pre-cured component extending along the length of the blade from a first inclined end configured to connect to a first complimentary inclined end of a spar cap of the first blade section and a second inclined end.

Abstract: A segmented rotor blade for a wind turbine includes a first rotor blade segment, a second rotor blade segment, at least one thermoplastic material, and an internal pressure source. The first rotor blade segment includes a first joint end. The second rotor blade segment includes a second joint end. The first and second joint ends are arranged together in an end-to-end orientation so as to form at least one scarf joint. The at least one thermoplastic material is arranged at each of the first and second joint ends. The first and second joint ends of the first and second rotor blade segments are bonded together via thermoplastic welding of the at least one thermoplastic material. The internal pressure source provides pressure to the scarf joint during the thermoplastic welding. The internal pressure source remains within the rotor blade after thermoplastic welding is complete.

Abstract: A composite member comprises first and second elongate composite elements. Each has a wedge shaped end with a complimentary tapered end surface. At least one of the components is formed of a stack of fiber layers impregnated in resin, with the tapered end surface being formed by each fiber layer extending longitudinally progressively further than the adjacent layer towards the thin end of the wedge at which the fiber layers have the greatest longitudinal extent. The components are joined at their tapered ends by an adhesive, and the properties of the cured composite material of the at least one component and/or the properties of the adhesive are different in the vicinity of the thin end of the wedge as compared to the rest of the tapered surface in order to reduce the stress concentrations in this region.

Abstract: An erosion resistant aerodynamic fairing for a rotor blade. A fairing body is formed from at least one reinforcing fiber layer set in a cured resin. An erosion resistant pre-form is fixed to an outer surface of the fairing body. The erosion resistant pre-form comprises a thermoplastic film outer layer fused to a fiber substrate. The fiber substrate of the erosion resistant pre-form is impregnated with the cured resin of the fairing body which fixes at the preform to the fairing body.

Abstract: A wind turbine blade which is at least 45 m long. The blade has a main axis in the lengthwise direction from root to tip and an aerodynamic shell surrounding a spar which extends in a lengthwise direction along a substantial proportion of the blade at least a portion of the half of the shell closest to the tip. The blade is reinforced by high stiffness fibers having a Young's modulus to density ratio of greater than 50 GPa/(g·cm?3), and an electrical resistivity of greater than 1010 ?·cm. The fibers are biaxial with a first axis angled with respect to the main axis at an acute angle and a second axis angled with respect to the main axis at an acute angle in the opposite sense to the first angle.

Abstract: A wind turbine rotor comprising a hub (1) from which a plurality of blades (2) project to a radius of at least 50 meters. Each blade comprising a hollow fairing supported by a central spar. Each blade has a thickness t at a radius r; characterized in that when r=0.5 R, t>0.3 T, where R is the radius of the blade and T is the thickness of the blade at the root end. By being thicker for a greater proportion of the blade, the aerodynamic performance of this part of the blade is worse, but this is more than compensated for as it allows better aerodynamic performance where it matters more, namely at the outer part of the blade. It also allows larger blades to be provided.

Abstract: A method of making a root end joint for a wind turbine. A plurality of root segments (10) are formed of a composite material. Each has an arcuate end face (11) which subtends an angle of 90° or less and has a plurality of connection holes (12). The segments are joined together side-by-side to build up the circular profile of the root end. The segments include a proportion of uni-axial to multiaxial fiber which decreases from the arcuate end face towards the opposite end.

Abstract: A wind turbine blade comprising first and second adjacent blade sections arranged end to end along the length of the blade. Each section comprises an aerodynamic fairing and a spar. Each spar comprises a shear web extending across the fairing and a pair of spar caps, one at either end of the shear web. Each spar cap in the first section has a different cross-sectional shape and/or material from the respective spar cap in the second section and wherein the spar cap in the first section is joined to the respective spar cap in the second section via a connection piece. Each connection piece is a pre-cured component extending along the length of the blade from a first inclined end configured to connect to a first complimentary inclined end of a spar cap of the first blade section and a second inclined end.

Abstract: A modular fiber reinforced plastic flange for a structural composite beam which comprises a body formed of a plurality of elongate elements arranged in an array, wherein the dimensions of the body are substantially determined by the number and arrangement of the elongate elements in the array, and a skin member at least partially surrounding the array. Also, a structural composite beam comprising the modular fiber reinforced plastic flange and a shear web connected to the skin member of the modular flange. A method of making the modular flange and beams, and a kit of parts for making the modular flange are also disclosed.

Abstract: An insert for forming an end connection in a uni-axial composite material, and an end connection comprising at least one insert, is disclosed. The insert comprises a sleeve which comprises a plurality of fibers having a multi-axial arrangement. At least a portion of the interior surface of the sleeve comprises a thread formation. A method of forming an end connection in a uni-axial composite material is also disclosed. The method comprises providing a sleeve comprising a plurality of fibers having a multi-axial arrangement and providing a thread formation on at least a portion of the interior surface of the sleeve. The sleeve is positioned and secured within the uni-axial composite material.