Abstract: Methods are provided for joining a composite component, such as a rotor blade of a wind turbine. Accordingly, a first blade segment is provided and a bladder assembly is positioned thereon. Additionally, an adhesive element is positioned in a first position on the first blade segment. A second blade segment is positioned with the first blade segment so as to define an inner cavity therebetween. The inner cavity contains the adhesive element and the bladder assembly, but the adhesive element does not contact the second blade segment while in the first position. The bladder assembly is inflated to transition the adhesive element to a second position in contact with both the first blade segment and the second blade segment. With the adhesive element in contact with both blade segments, the adhesive element is allowed to cure in order to secure the blade segments to one another.

Abstract: A method of forming a rotor blade includes positioning first dry skin layer(s) in a first mold. The method also includes placing a wedge-shaped core material having a mounting surface atop the first dry skin(s) in the first mold at a trailing edge end of the rotor blade. The method further includes infusing the first dry skin layer(s) and the core material together via a resin material to form a first shell member. The method includes applying an adhesive onto the mounting surface and then placing a second mold with a second shell member arranged therein atop the first mold containing the first shell member to form the rotor blade such that a portion of the second shell member rests atop the mounting surface. Thus, the method includes securing the shell members together via the adhesive, wherein the core material supports the trailing edge end of the rotor blade.

Abstract: A method for joining rotor blade segments of a rotor blade includes placing a first blade segment in an assembly fixture. The assembly fixture has an outer carrier and at least one bladder arranged with the outer carrier. The first blade segment has an adhesive applied at one or more locations. The method also includes arranging the first blade segment with a second blade segment at at least one joint using the assembly fixture with the adhesive positioned at the at least one joint. Further, the method includes inflating the at least one bladder to provide pressure to the at least one joint, wherein the pressure causes the adhesive to displace between the first and second blade segments at the at least one joint, thereby securing the first and second blade segments together at the at least one joint. Moreover, the method includes maintaining the pressure via the at least one inflated bladder to allow the adhesive to cure, thereby securing the first and second blade segments together.

Abstract: A method for joining rotor blade segments of a rotor blade includes forming a female structural member having a receipt portion with a cavity and a structural portion. Further, the method includes securing the female structural member within a first blade segment. The method also includes forming a male structural member having a protrusion portion and a structural portion. Moreover, the method includes securing the structural portion of the male structural member within a second blade segment. In addition, the method includes inserting the protrusion portion into the cavity. As such, when inserted, an interface of the protrusion portion and the cavity forms one or more internal channels. Thus, the method further includes injecting adhesive into the one or more internal channels so as to secure the first and second blade segments together.

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 method for joining rotor blade segments of a rotor blade includes forming a female structural member having a receipt portion with a cavity and a structural portion. Further, the method includes securing the female structural member within a first blade segment. The method also includes forming a male structural member having a protrusion portion and a structural portion. Moreover, the method includes securing the structural portion of the male structural member within a second blade segment. In addition, the method includes inserting the protrusion portion into the cavity. As such, when inserted, an interface of the protrusion portion and the cavity forms one or more internal channels. Thus, the method further includes injecting adhesive into the one or more internal channels so as to secure the first and second blade segments together.

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 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: 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 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: 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.

Abstract: A wind turbine blade comprising an elongate spar (6). A first plurality of skin panels (1) are attached in an upper high pressure row to the spar to form a substantial proportion of the external profile of one surface of the blade. A second plurality of skin panels (1) are attached in a lower low pressure row to the spar to form a substantial proportion of the external profile of the opposite lower surface of the blade. A plurality of the skin panels in each row are each integrally provided with a bulkhead (2) which supports the skin panel on the spar.

Abstract: A method for connecting adjacent parts (1A, 1B) of a wind turbine fairing. Two parts are abutted together to define an adhesive channel (14) between the two parts and a pair of spacers (12, 13). Adhesive is injected into the channel. One of the parts is provided with a stop (16) on a surface which is internal to the fairing allowing the two parts to be located correctly with respect to one another.

Abstract: A wind turbine blade comprising an elongate spar (6). A first plurality of skin panels (1) are attached in an upper high pressure row to the spar to form a substantial proportion of the external profile of one surface of the blade. A second plurality of skin panels (1) are attached in a lower low pressure row to the spar to form a substantial proportion of the external profile of the opposite lower surface of the blade. A plurality of the skin panels in each row are each integrally provided with a bulkhead (2) which supports the skin panel on the spar.

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 fibres 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 fibres 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.