Abstract: The present disclosure is directed to a method for forming a wind turbine rotor blade. The method includes placing first and second prefabricated skin panels defining a portion of a root section of the wind turbine rotor blade, a pressure side of the wind turbine rotor blade, or a suction side of the wind turbine rotor blade in a mold. The first and second prefabricated skin panels partially overlap to define a connection region. A vacuum bag is placed over the mold. The connection region is infused with a resin.

Abstract: The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof. In one embodiment, the method includes forming an outer surface of a rotor blade panel from one or more fiber-reinforced outer skins. The method also includes printing and depositing at least one reinforcement structure onto an inner surface of the one or more fiber-reinforced outer skins to form the rotor blade panel, wherein the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited.

Abstract: The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof. In one embodiment, the method includes forming an outer surface of a rotor blade panel from one or more fiber-reinforced outer skins. The method also includes printing and depositing at least one reinforcement structure onto an inner surface of the one or more fiber-reinforced outer skins to form the rotor blade panel, wherein the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited.

Abstract: The present disclosure is directed to a method of manufacturing a rotor blade component of a wind turbine is disclosed. The method includes placing at least one first pultruded member into a curved rotor blade component mold. More specifically, the first pultruded member includes at least one design characteristic configured to allow the first pultruded member to sit substantially flush against an inner surface of the curved rotor blade component mold. The method also includes placing at least one second pultruded member atop the at least one first pultruded member and infusing the first and second pultruded members together to form the rotor blade component.

Abstract: The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof, e.g. using 3D printing. In one embodiment, the method includes forming a rotor blade structure having a first surface and an opposing, second surface, the first and second surfaces being substantially flat. Another step includes printing a leading edge segment of the rotor blade onto the first surface, wherein heat from the printing bonds the leading edge segment to the first surface. The method also includes rotating the rotor blade structure having the leading edge segment attached thereto. A further step includes printing a trailing edge segment of the rotor blade onto the second surface, wherein heat from the printing bonds the trailing edge segment to the second surface. Another step includes securing one or more fiber-reinforced outer skins to the leading and trailing edge segments so as to complete the rotor blade.

Abstract: Wind turbine rotor blade components including pultruded rods and methods of manufacturing the same are disclosed. More specifically, the rotor blade component includes a plurality of pultruded rods housed within an enclosed primary outer casing. The enclosed primary outer casing includes a hollow interior, a root end, and an opposing tip. As such, each of the plurality of pultruded rods is received within the enclosed primary outer casing and secured therein via a first resin material. Further, an arrangement of the plurality of pultruded rods within the primary outer casing and a relationship of a maximum dimension of each of the plurality of pultruded rods and a maximum dimension of the enclosed primary outer casing are configured to maximize flexibility of the rotor blade component.

Abstract: A wind turbine blade shell component is made by providing a plurality of first pultrusion plates formed of a first fiber material, and a plurality of second pultrusion plates formed of a second fiber material. The first and second pultrusion plates are stacked in a hybrid pattern that includes a first section containing a plurality of the first and second pultrusion plates having a length shorter than an entire length of a spar cap for a wind turbine blade shell, and a core section having a continuous unbroken length of the second fiber material corresponding to an entire length of the spar cap. The stacked pattern is arranged on blade shell materials in a mold for the blade shell component and is bonded with the blade shell materials to form the blade shell component.

Abstract: A wind turbine blade component is made by providing a plurality of first pultrusion plates formed of a first pultrusion fiber material, and a plurality of second pultrusion plates formed of a second pultrusion fiber material. The first and second pultrusion plates have a length corresponding to an entire length of a spar cap for a wind turbine blade shell. The first and second pultrusion plates are stacked in a hybrid pattern that contains both first and second pultrusion plates, and the stack is arranged on blade shell material in a mold for the blade shell. The stacked hybrid pattern of first and second pultrusion plates is bonded with the blade shell materials to form an integral blade shell and bonded spar cap component.

Abstract: The present disclosure is directed to tip extensions for wind turbine rotor blades and methods of installing same. The method includes removing a removable blade tip of a lightning protection system from the rotor blade so as to expose a down conductor of the lightning protection system. The method also includes securing a conductive extension to the down conductor. Moreover, the method includes sliding the first end of the tip extension over the conductive extension so as to overlap the rotor blade at the tip end. In addition, the method includes securing the removable blade tip to the conductive extension at the second end of the tip extension. Further, the method includes securing the tip extension to the rotor blade.

Abstract: The present disclosure is directed to a system and method for reducing electrical arcs caused by lightning strikes in a rotor blade of a wind turbine. The rotor blade includes a lightning protection system with at least one lightning receptor connected to at least one conductor and a conduit assembly. The conduit assembly has one or more conduit members configured to route the conductor of the lightning protection system from a first blade location to a second blade location so as to maximize a distance between the conductor and one or more conductive rotor blade components.

Abstract: Wind turbine rotor blade components including pultruded rods and methods of manufacturing the same are disclosed. More specifically, the rotor blade component includes a plurality of pultruded rods housed within an enclosed primary outer casing. The enclosed primary outer casing includes a hollow interior, a root end, and an opposing tip. As such, each of the plurality of pultruded rods is received within the enclosed primary outer casing and secured therein via a first resin material. Further, an arrangement of the plurality of pultruded rods within the primary outer casing and a relationship of a maximum dimension of each of the plurality of pultruded rods and a maximum dimension of the enclosed primary outer casing are configured to maximize flexibility of the rotor blade component.

Abstract: A wind turbine blade component is made by providing a plurality of first pultrusion plates formed of a first pultrusion fiber material, and a plurality of second pultrusion plates formed of a second pultrusion fiber material. The first and second pultrusion plates have a length corresponding to an entire length of a spar cap for a wind turbine blade shell. The first and second pultrusion plates are stacked in a hybrid pattern that contains both first and second pultrusion plates, and the stack is arranged on blade shell material in a mold for the blade shell. The stacked hybrid pattern of first and second pultrusion plates is bonded with the blade shell materials to form an integral blade shell and bonded spar cap component.

Abstract: A wind turbine blade shell component is made by providing a plurality of first pultrusion plates formed of a first fiber material, and a plurality of second pultrusion plates formed of a second fiber material. The first and second pultrusion plates are stacked in a hybrid pattern that includes a first section containing a plurality of the first and second pultrusion plates having a length shorter than an entire length of a spar cap for a wind turbine blade shell, and a core section having a continuous unbroken length of the second fiber material corresponding to an entire length of the spar cap. The stacked pattern is arranged on blade shell materials in a mold for the blade shell component and is bonded with the blade shell materials to form the blade shell component.

Abstract: The present disclosure is directed to a method of manufacturing a rotor blade component of a wind turbine is disclosed. The method includes placing at least one first pultruded member into a curved rotor blade component mold. More specifically, the first pultruded member includes at least one design characteristic configured to allow the first pultruded member to sit substantially flush against an inner surface of the curved rotor blade component mold. The method also includes placing at least one second pultruded member atop the at least one first pultruded member and infusing the first and second pultruded members together to form the rotor blade component.

Abstract: The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof, e.g. using 3D printing. In one embodiment, the method includes forming a rotor blade structure having a first surface and an opposing, second surface, the first and second surfaces being substantially flat. Another step includes printing a leading edge segment of the rotor blade onto the first surface, wherein heat from the printing bonds the leading edge segment to the first surface. The method also includes rotating the rotor blade structure having the leading edge segment attached thereto. A further step includes printing a trailing edge segment of the rotor blade onto the second surface, wherein heat from the printing bonds the trailing edge segment to the second surface. Another step includes securing one or more fiber-reinforced outer skins to the leading and trailing edge segments so as to complete the rotor blade.

Abstract: The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof. In one embodiment, the method includes forming an outer surface of a rotor blade panel from one or more fiber-reinforced outer skins. The method also includes printing and depositing at least one reinforcement structure onto an inner surface of the one or more fiber-reinforced outer skins to form the rotor blade panel, wherein the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited.

Abstract: The present disclosure is directed to a method for forming a wind turbine rotor blade. The method includes placing first and second prefabricated skin panels defining a portion of a root section of the wind turbine rotor blade, a pressure side of the wind turbine rotor blade, or a suction side of the wind turbine rotor blade in a mold. The first and second prefabricated skin panels partially overlap to define a connection region. A vacuum bag is placed over the mold. The connection region is infused with a resin.

Abstract: The present disclosure is directed to tip extensions for wind turbine rotor blades and methods of installing same. The method includes removing a removable blade tip of a lightning protection system from the rotor blade so as to expose a down conductor of the lightning protection system. The method also includes securing a conductive extension to the down conductor. Moreover, the method includes sliding the first end of the tip extension over the conductive extension so as to overlap the rotor blade at the tip end. In addition, the method includes securing the removable blade tip to the conductive extension at the second end of the tip extension. Further, the method includes securing the tip extension to the rotor blade.

Abstract: The present disclosure is directed to a system and method for reducing electrical arcs caused by lightning strikes in a rotor blade of a wind turbine. The rotor blade includes a lightning protection system with at least one lightning receptor connected to at least one conductor and a conduit assembly. The conduit assembly has one or more conduit members configured to route the conductor of the lightning protection system from a first blade location to a second blade location so as to maximize a distance between the conductor and one or more conductive rotor blade components.

Abstract: A system for containing or transporting wind turbine components is provided. The system includes at least one container for receiving at least a portion of the wind turbine components, and the wind turbine components are arranged within the container in a nested configuration.