Abstract: Systems and methods for joining blade components of a rotor blade are provided. A method includes positioning a first blade component and a second blade component such that a joint location of the first blade component and a joint location of the second blade component are proximate each other. The method further includes applying a force to an outer surface of the second blade component and an opposing force to an inner surface of the second blade component. The force and opposing force maintain an aerodynamic contour of the second blade component. The method further includes connecting the joint location of the first blade component and the joint location of the second blade component together.

Abstract: The present disclosure is directed to a method of assembly of a rotor blade for a wind turbine. The method includes placing a first rotor blade section onto a first set location of an assembly fixture, wherein the first rotor blade includes a first locating datum such that the assembly fixture at the first set location constrains movement of the first rotor blade section at the first locating datum along a first direction; placing the first rotor blade section onto a second set location of the assembly fixture, wherein the first rotor blade includes a second locating datum such that the assembly fixture at the second set location constrains movement of the first rotor blade section at the second locating datum along a second direction; and positioning a second rotor blade section onto the first rotor blade section within the assembly fixture.

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.

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: A jointed rotor blade assembly may include a first blade segment having a first outer shell terminating at a first joint end and a second blade segment coupled to the first blade segment at a blade joint. The second blade segment may include a second outer shell terminating at a second joint end. The outer shells may overlap one another at the blade joint such that an overlapping region is defined between the first and second joint ends. In addition, the first outer shell may be spaced apart from the second outer shell along at least a portion of the overlapping region such that a gap is defined between the outer shells within the overlapping region. Moreover, the rotor blade assembly may include a sealing member positioned between the outer shells within the overlapping region that is configured to allow relative movement between the outer shells at the blade joint.

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.

Abstract: The present disclosure is directed to a method for manufacturing a blade component for a rotor blade of a wind turbine. The method includes arranging a fiber material in a mold of the blade component. The method also includes placing at least one pre-cured laminate material atop the fiber material. Another step includes infusing the fiber material and the pre-cured laminate material together via a resin material so as to form the blade component. The method also includes allowing the blade component to cure, the pre-cured laminate material forming at least a portion of an outer surface of the blade component.

Abstract: The present disclosure is directed to methods for joining rotor blade components using thermoplastic welding.

Abstract: A method for manufacturing a root section of a wind turbine blade includes assembling a mold having an inner cylinder segment, an outer cylinder segment, and a bottom flange, wherein a radial space is defined between the inner and outer cylinders. Root hub connectors are attached circumferentially around the bottom flange so that the root hub connectors extend axially into the radial space. A first cartridge of pultruded rods is loaded into the space, wherein the first cartridge includes a plurality of first pultruded rods arranged adjacent to the inner cylinder segment. The space is sealed, for example with a lid or top flange, and the space is evacuated. A resin is infused into the space so that the resin migrates through the radial space between the pultruded rods, and is then cured. The root section is then removed from the mold. A wind turbine blade root section formed by the method is encompassed by the invention.

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.

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: 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.

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.

Abstract: A wind turbine rotor blade may generally include a blade root, a blade tip opposite the blade root and a body shell extending between the blade root and the blade tip. The body shell may include a pressure side and a suction side extending between a leading edge and a trailing edge and may define an outer shell surface. The rotor blade may also include a leading edge cap coupled to the body shell at the leading edge. The leading edge cap may be formed from a fiber-reinforced composite including an inner surface extending directly adjacent to the body shell along a portion of the outer shell surface and an outer surface opposite the inner surface. The fiber-reinforced composite may include a plurality of fibers surrounded by a thermoplastic resin material, with the thermoplastic resin material extending throughout the fiber reinforced composite from the inner surface to the outer surface.

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 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.

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.

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.

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: 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.