Granted Patent B2

US 12,366,226 · App. 18/019,686 · Granted Jul 22, 2025

Inventors: Manish Mukherjee (Hampshire, GB); Michael Haag (Kolding, DK)

Assignees: BLADE DYNAMICS LIMITED; LM WIND POWER A/S

F03D1/0675F03D1/0688F03D80/50F05B2240/303F05B2280/6003F05B2280/6011

Abstract

Claims (77)

1. A wind turbine blade extending from a root end to a tip end, the wind turbine blade comprising a root region, and an airfoil region comprising the tip, a pressure side, a suction side and a chord extending between a leading edge and a trailing edge,

the wind turbine blade comprising a blade shell made of a composite material comprising fibre-reinforcement material embedded in a polymer material,

the wind turbine blade further comprising a leading edge protection element at the leading edge of the wind turbine blade, the leading edge protection element extending in a longitudinal direction between an outboard end and an inboard end and comprising:

a first section extending from the outboard end to a first section position, wherein the first section is made of a first erosion protection material having a first erosion resistance, wherein the first erosion protection material comprises one or more of a nickel-based alloy or titanium;

a second section extending from the first section position to a second section position, wherein the second section is made of a second erosion protective material having a second erosion resistance, wherein the second erosion protection material comprises a polymer material comprising one or more of thermoplastic polyurethanes, UHMWPE, PEEK, polycarbonate or ABS; and

a third section extending from the second section position to the inboard end, wherein the third section is made of a third erosion protection material having a third erosion resistance, and wherein the first erosion resistance and the second erosion resistance are larger than the third erosion resistance, wherein the third erosion protection material comprises one or more of:

a paint system material comprising conventional 2-component aliphatic polyurethane or 2-component epoxy; or

a gelcoat material comprising epoxy, polyester or polyurethane,

wherein the first erosion resistance is larger than the second erosion resistance,

wherein the leading edge protection element is distinct from the composite material of the blade shell, and

wherein a length of the first section measured between the outboard end and the first section position is between 1-15% of a blade length of the wind turbine blade.

2. The wind turbine blade according to claim 1 , wherein the leading edge protection element is embedded in the blade shell of the leading edge of the wind turbine blade.

3. The wind turbine blade according to claim 1 , wherein the leading edge protection element is attached to an outer surface of the blade shell of the leading edge of the wind turbine blade.

4. The wind turbine blade according to claim 1 , wherein a length of the leading edge protection element measured between the outboard end to the inboard end is at least 30% of the blade length of the wind turbine blade.

5. A method for protecting a leading edge of a wind turbine blade, the method comprising:

providing the wind turbine blade, wherein the wind turbine blade extends from a root end to a tip end, and comprising a root region, and an airfoil region comprising the tip, a pressure side, a suction side and a chord extending between the leading edge and a trailing edge, and wherein the wind turbine blade comprises a blade shell made of a composite material comprising fibre-reinforcement material embedded in a polymer material,

providing a leading edge protection element at the leading edge of the wind turbine blade, the leading edge protection element extending in a longitudinal direction between an outboard end and an inboard end and comprising:

a first section extending from the outboard end to a first section position, wherein the first section is made of a first erosion protection material having a first erosion resistance, wherein the first erosion protection material comprises one or more of a nickel-based alloy or titanium;

a second section extending from the first section position to a second section position, wherein the second section is made of a second erosion protective material having a second erosion resistance, wherein the second erosion protection material comprises a polymer material comprising one or more of thermoplastic polyurethanes, UHMWPE, PEEK, polycarbonate or ABS; and

a third section extending from the second section position to the inboard end, wherein the third section is made of a third erosion protection material having a third erosion resistance, and wherein the first erosion resistance and the second erosion resistance are larger than the third erosion resistance, wherein the third erosion protection material comprises one or more of:

a paint system material comprising conventional 2-component aliphatic polyurethane or 2-component epoxy; or

a gelcoat material comprising epoxy, polyester or polyurethane,

wherein the first erosion resistance is larger than the second erosion resistance, and

wherein the leading edge protection element is distinct from the composite material of the blade shell, and

attaching the leading edge protection element to at least part of the leading edge of the wind turbine blade,

wherein a length of the first section measured between the outboard end and the first section position is between 1-15% of a blade length of the wind turbine blade.

6. A wind turbine blade extending from a root end to a tip end, the wind turbine blade comprising a root region, and an airfoil region comprising the tip, a pressure side, a suction side and a chord extending between a leading edge and a trailing edge,

the wind turbine blade comprising a blade shell made of a composite material comprising fibre-reinforcement material embedded in a polymer material,

the wind turbine blade further comprising a leading edge protection element at the leading edge of the wind turbine blade, the leading edge protection element extending in a longitudinal direction between an outboard end and an inboard end and comprising:

a first section extending from the outboard end to a first section position, wherein the first section is made of a first erosion protection material having a first erosion resistance, wherein the first erosion protection material comprises one or more of a nickel-based alloy or titanium;

a second section extending from the first section position to a second section position, wherein the second section is made of a second erosion protective material having a second erosion resistance, wherein the second erosion protection material comprises a polymer material comprising one or more of thermoplastic polyurethanes, UHMWPE, PEEK, polycarbonate or ABS; and

a third section extending from the second section position to the inboard end, wherein the third section is made of a third erosion protection material having a third erosion resistance, and wherein the first erosion resistance and the second erosion resistance are larger than the third erosion resistance, wherein the third erosion protection material comprises one or more of:

a paint system material comprising conventional 2-component aliphatic polyurethane or 2-component epoxy; or

a gelcoat material comprising epoxy, polyester or polyurethane,

wherein the first erosion resistance is larger than the second erosion resistance,

wherein the leading edge protection element is distinct from the composite material of the blade shell, and

wherein a length of the second section measured between the first section position and the second section position is between 15-25% of a blade length of the wind turbine blade.

7. The wind turbine blade according to claim 6 , wherein the leading edge protection element is embedded in the blade shell of the leading edge of the wind turbine blade.

8. The wind turbine blade according to claim 6 , wherein the leading edge protection element is attached to an outer surface of the blade shell of the leading edge of the wind turbine blade.

9. The wind turbine blade according to claim 6 , wherein a length of the leading edge protection element measured between the outboard end to the inboard end is at least 30% of the blade length of the wind turbine blade.

10. A wind turbine blade extending from a root end to a tip end, the wind turbine blade comprising a root region, and an airfoil region comprising the tip, a pressure side, a suction side and a chord extending between a leading edge and a trailing edge,

the wind turbine blade comprising a blade shell made of a composite material comprising fibre-reinforcement material embedded in a polymer material,

the wind turbine blade further comprising a leading edge protection element at the leading edge of the wind turbine blade, the leading edge protection element extending in a longitudinal direction between an outboard end and an inboard end and comprising:

a first section extending from the outboard end to a first section position, wherein the first section is made of a first erosion protection material having a first erosion resistance, wherein the first erosion protection material comprises one or more of a nickel-based alloy or titanium;

a second section extending from the first section position to a second section position, wherein the second section is made of a second erosion protective material having a second erosion resistance, wherein the second erosion protection material comprises a polymer material comprising one or more of thermoplastic polyurethanes, UHMWPE, PEEK, polycarbonate or ABS; and

a third section extending from the second section position to the inboard end, wherein the third section is made of a third erosion protection material having a third erosion resistance, and wherein the first erosion resistance and the second erosion resistance are larger than the third erosion resistance, wherein the third erosion protection material comprises one or more of:

a paint system material comprising conventional 2-component aliphatic polyurethane or 2-component epoxy; or

a gelcoat material comprising epoxy, polyester or polyurethane,

wherein the first erosion resistance is larger than the second erosion resistance,

wherein the leading edge protection element is distinct from the composite material of the blade shell, and

wherein a length of the third section measured between the second section position and the inboard end is between 55-85% of a blade length of the wind turbine blade.

11. The wind turbine blade according to claim 10 , wherein the leading edge protection element is embedded in the blade shell of the leading edge of the wind turbine blade.

12. The wind turbine blade according to claim 10 , wherein the leading edge protection element is attached to an outer surface of the blade shell of the leading edge of the wind turbine blade.

13. A method for protecting a leading edge of a wind turbine blade, the method comprising:

providing the wind turbine blade, wherein the wind turbine blade extends from a root end to a tip end, and comprising a root region, and an airfoil region comprising the tip, a pressure side, a suction side and a chord extending between the leading edge and a trailing edge, and wherein the wind turbine blade comprises a blade shell made of a composite material comprising fibre-reinforcement material embedded in a polymer material,

providing a leading edge protection element at the leading edge of the wind turbine blade, the leading edge protection element extending in a longitudinal direction between an outboard end and an inboard end and comprising:

a first section extending from the outboard end to a first section position, wherein the first section is made of a first erosion protection material having a first erosion resistance, wherein the first erosion protection material comprises one or more of a nickel-based alloy or titanium;

a second section extending from the first section position to a second section position, wherein the second section is made of a second erosion protective material having a second erosion resistance, wherein the second erosion protection material comprises a polymer material comprising one or more of thermoplastic polyurethanes, UHMWPE, PEEK, polycarbonate or ABS; and

a third section extending from the second section position to the inboard end, wherein the third section is made of a third erosion protection material having a third erosion resistance, and wherein the first erosion resistance and the second erosion resistance are larger than the third erosion resistance, wherein the third erosion protection material comprises one or more of:

a paint system material comprising conventional 2-component aliphatic polyurethane or 2-component epoxy; or

a gelcoat material comprising epoxy, polyester or polyurethane,

wherein the first erosion resistance is larger than the second erosion resistance, and

wherein the leading edge protection element is distinct from the composite material of the blade shell, and

attaching the leading edge protection element to at least part of the leading edge of the wind turbine blade,

wherein a length of the second section measured between the first section position and the second section position is between 15-25% of a blade length of the wind turbine blade.

14. A method for protecting a leading edge of a wind turbine blade, the method comprising:

providing the wind turbine blade, wherein the wind turbine blade extends from a root end to a tip end, and comprising a root region, and an airfoil region comprising the tip, a pressure side, a suction side and a chord extending between the leading edge and a trailing edge, and wherein the wind turbine blade comprises a blade shell made of a composite material comprising fibre-reinforcement material embedded in a polymer material,

providing a leading edge protection element at the leading edge of the wind turbine blade, the leading edge protection element extending in a longitudinal direction between an outboard end and an inboard end and comprising:

a first section extending from the outboard end to a first section position, wherein the first section is made of a first erosion protection material having a first erosion resistance, wherein the first erosion protection material comprises one or more of a nickel-based alloy or titanium;

a second section extending from the first section position to a second section position, wherein the second section is made of a second erosion protective material having a second erosion resistance, wherein the second erosion protection material comprises a polymer material comprising one or more of thermoplastic polyurethanes, UHMWPE, PEEK, polycarbonate or ABS; and

a third section extending from the second section position to the inboard end, wherein the third section is made of a third erosion protection material having a third erosion resistance, and wherein the first erosion resistance and the second erosion resistance are larger than the third erosion resistance, wherein the third erosion protection material comprises one or more of:

a paint system material comprising conventional 2-component aliphatic polyurethane or 2-component epoxy; or

a gelcoat material comprising epoxy, polyester or polyurethane,

wherein the first erosion resistance is larger than the second erosion resistance, and

wherein the leading edge protection element is distinct from the composite material of the blade shell, and

attaching the leading edge protection element to at least part of the leading edge of the wind turbine blade,

wherein a length of the third section measured between the second section position and the inboard end is between 55-85% of a blade length of the wind turbine blade.

Assignments (1)

Priority Claims (1)

Continuity (1)

References Cited (29)