Thermoplastic airflow modifying elements for wind turbine rotor blades
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.
1. A method for securing one or more airflow modifying elements to an outer surface of a rotor blade for a wind turbine, the method comprising:
placing an outer skin layer of composite material in a mold of a blade shell of the rotor blade to form the outer surface of the rotor blade;
arranging one or more pre-cured layers of thermoplastic material in the mold of the blade shell of the rotor blade with the outer surface so as to define one or more attachment locations;
infusing the outer skin layer and the one or more pre-cured layers of thermoplastic material via a resin material so as to form the rotor blade;
curing the rotor blade;
removing at least a portion of the outer skin layer to reveal the one or more attachment locations; and
subsequently welding at least one airflow modifying element constructed, at least in part, from a thermoplastic material, to at least one of the attachment locations.
2. The method of claim 1 wherein the resin material comprises a thermoset material.
3. The method of claim 2 , further comprising:
placing at least one fiber material in the mold;
infusing the outer skin layer, the one or more pre-cured layers of thermoplastic material, and the fiber material together via the thermoset material so as to form the rotor blade.
4. The method of claim 1 , wherein removing at least a portion of the outer skin layer to reveal the one or more attachment locations further comprises at least one of sanding, grinding, or machining the outer skin layer to reveal the one or more attachment locations therebeneath.
5. The method of claim 1 , further comprising forming the at least one airflow modifying element via a thermoplastic material and at least one fiber reinforcement material, the at least one airflow modifying element comprising at least one of vortex generators, chord extensions, fairings, low noise trailing edge serrations, leading edge extensions, trailing edge extensions, spoilers, fairings, gurney flaps, stakes, or protrusions.
6. A method for manufacturing a rotor blade of a wind turbine, the method comprising:
placing an outer skin layer of composite material in a mold of a blade shell to form the outer surface of the rotor blade;
placing at least one of a fiber material or a core material in the mold atop the outer skin layer;
placing one or more pre-cured layers of thermoplastic material in the mold of the blade shell so as to define one or more attachment locations;
infusing the outer skin layer, at least one of the fiber material or the core material, and the one or more pre-cured layers together via at least one of a thermoset material or a thermoplastic material so as to form the rotor blade;
allowing the rotor blade to cure;
removing at least a portion of the outer skin layer to reveal the one or more attachment locations; and,
subsequently welding at least one airflow modifying element constructed, at least in part, from a thermoplastic material, to an attachment location of the cured rotor blade.
7. The method of claim 6 , wherein the fiber material comprises at least one of glass fibers, carbon fibers, polymer fibers, ceramic fibers, nanofibers, or metal fibers.
8. The method of claim 6 , further comprising forming the airflow modifying element via the thermoplastic material and at least one fiber reinforcement material.
9. The method of claim 8 , wherein the at least one airflow modifying element further comprises at least one of vortex generators, chord extensions, fairings, low noise trailing edge serrations, leading edge extensions, trailing edge extensions, spoilers, fairings, gurney flaps, stakes, or protrusions.