Method of shaping an edge seal for a rotor blade add-on

1. A method of shaping an initial edge seal along a longitudinal edge step of an add-on part mounted on an outer surface of a rotor blade, which method comprises:

providing the initial edge seal along the longitudinal edge step of the add-on part mounted on the outer surface of the rotor blade,

removing a top layer of the initial edge seal.

2. The method according to claim 1 , wherein the provision of the initial edge seal comprises the step of sealing the longitudinal edge step of the add-on part mounted on the outer surface of the rotor blade, wherein liquid sealant is applied.

3. The method according to claim 2 , wherein a width of the initial edge seal is tuned in order to reduce the aerodynamic impact of the longitudinal edge step due to interfacing surfaces based on wind tunnel measurements.

4. The method according to claim 1 , wherein the initial edge seal is overlapping with the add-on part.

5. The method according to claim 4 , comprising a step of determining a width of an edge seal overlap in an overlap region adjacent to the longitudinal edge step of the add-on part, wherein an overlap width is determined on the basis of a height at the longitudinal edge step of the add-on part.

6. The method according to claim 5 , wherein the ratio of width and/or overlap width to height at the longitudinal edge step is bigger than 4:1 and/or smaller than 100:1.

7. The method according to claim 1 , comprising:

providing the initial edge seal,

delimiting an application area on the rotor blade surface and the add-on part to be covered by sealant compound with a thin and smooth masking tape,

dispensing of the sealant compound on the application area, wherein the sealant compound is applied in a serpentine line overlapping a transition between the add-on and the blade surface,

distributing the sealant compound, by using a flexible toothed spatula, or smoothening the sealant compound with a, flexible, tool moved in the longitudinal direction of the blade, wherein the tool is so configured to meet the profile of the blade, removing the masking tape, and

smoothening of a sealant transition step with a flexible tool, with a Shore A hardness between 40 and 60.

8. The method according to claim 7 , wherein the sealant compound has a maximum size of solid particles, filler particles, agglomerates of filler particles or gel particles in the sealant compound both in its liquid as well as hardened or cross-linked state, that is limited to max. 200 μm, or limited to max. 60 μm.

9. The method according to claim 7 , wherein before dispensing of the sealant compound on the application area a filler is first applied along the longitudinal add-on edge, wherein the filler is a quick-setting adhesive and/or a high-viscosity adhesive, and the sealant compound is applied over the cured or hardened filler.

10. The method according to claim 7 , wherein the sealant compound comprises the same material as an adhesive used for fixing the add-on on the rotor blade surface.

11. The method according to claim 1 , wherein removing a top layer of the initial edge seal is done by machining, by grinding and/or sanding and/or cutting and/or milling, so that the resulting edge seal is flush with the edge step.

12. The method according to claim 1 , wherein an angle between a surface of a resulting edge seal and a surface of the rotor blade is smaller at a point of the edge step as it is at a point where the resulting edge seal transitions into the rotor blade surface, wherein the resulting edge seal has a shape of a wedge with a convex surface or a kink in its surface.

13. A wind turbine rotor blade comprising at least one add-on part mounted to an outer surface of a rotor blade and an edge seal shaped by providing an initial edge seal along a longitudinal edge step of the at least one add-on part mounted on the outer surface of the rotor blade, and removing a top layer of the initial edge seal.

14. The wind turbine rotor blade according to claim 13 , wherein the at least one add-on part comprises any of a leading-edge protective cover, a trailing edge panel, a base plate, a vortex generator panel, a slat, a plate, a spoiler, flaps and/or a sensor panel.

15. The wind turbine rotor blade according to claim 13 , wherein a thickness of the at least one add-on part at its longitudinal edge step is in the range 0.2 mm to 5 mm, or 0.25-2 mm.