General Electric Company

Essilor International (compagnie Generale D'optique)

Ge Infrastructure Technology, LLC

The Ohio State University

Omnova Solutions Inc.

Oakland University

Essilor International

General Electric Renovables Espana, S.l.

Xu Chen

Scott Iverson Shillig

Louis Rondeau

Andrew Mitchell Rodwell

Scott Jacob Huth

Hsinjin E Yang

Stephen Bertram Johnson

Thomas Merzhaeuser

Amir Riahi

Joey Oliveros Obordo

Matthew James Lockwood

Julie Ann Shepherd

Aaron Alpheus Yarbrough

Jamie Thomas Livingston

Ronald A Berzon

Alan Majors Walker

Robert Alan Valeri

Elliott Straus

Nicholas Keane Althoff

Hoa Thien Dang

Lianxiang Yang

Nan Xu

Ronald Harmon

Swapnil Dhumal

Jose M Castro

Mattew James Lockwood

Xin Xie

Matthew Lockwood

Nan Xue

A method for manufacturing a structural component of a blade segment for a segmented rotor blade of a wind turbine includes forming first and second portions of the structural component. The first and second portions include respective holes that align in a chord-wise direction. The method also includes placing the first and second portions of the structural component into a mold such that their respective holes align in the chord-wise direction. Further, the method includes placing a tooling pin through the aligned holes. In addition, the method includes infusing the first and second sides together in the second mold via a resin material so as to form the structural component. Moreover, the method includes removing the tooling pin after the structural component has cured.

Method for manufacturing a structural component of a blade segment for a rotor blade of a wind turbine

A method for producing a hollow composite structure, such as a spar beam for use in a wind turbine blade, includes placing fiber reinforcement material around a mandrel within a mold, and curing the fiber reinforcement material. The mandrel is formed from a compressible material having a rigid neutral state with a rigidity to maintain a defined shape of the mandrel during lay up and curing of the fiber reinforcement material. Subsequent to curing, a vacuum is drawn on the mandrel to compress the compressible material so that the compressed mandrel can be drawn out through an opening in the composite structure, the opening having a size such that the mandrel could not be withdrawn through the opening in the rigid neutral state of the mandrel.

Method for manufacturing a hollow composite structure, particularly a spar beam for a wind turbine rotor blade, and an associated mandrel

A method for manufacturing a structural component of a blade segment for a rotor blade includes providing a mold of the structural component having an outer wall that defines an outer surface of the structural component. The method also includes laying up one or more fiber layers in the mold so as to at least partially cover the outer wall. As such, the fiber layer(s) form the outer surface of the structural component. Further, the method includes providing one or more metal mesh layers having one or more ends. Moreover, the method includes providing a cover material to the end(s) of the metal mesh layer(s). In addition, the method includes placing the metal mesh layer(s) with the covered end(s) atop the fiber layer(s). Thus, the method includes infusing the fiber layer(s) and the metal mesh layer(s) together via a resin material so as to form the structural component.

A method for manufacturing a structural component of a blade segment for a segmented rotor blade of a wind turbine includes providing a mold of the structural component. The mold has an outer wall that defines an outer surface of the structural component. The method also includes securing at least one tooling pin to the outer wall for defining a pin joint slot in the structural component. Further, the method includes laying up one or more outer fiber layers in the mold so as to at least partially cover the outer wall. The outer fiber layer(s) has at least one hole that receives the tooling pin(s). As such, the outer fiber layer(s) form the outer surface of the structural component. Moreover, the method includes placing one or more structural features atop the outer fiber layer(s) in the mold. In addition, the method includes infusing the outer fiber layer(s) and the structural feature(s) together via a resin material so as to form the structural component.

A method for producing a hollow composite structure, such as a spar beam for a wind turbine blade, includes placing a membrane within a mold tool, the membrane being permeable to air and impermeable to resin. A mandrel is placed within the mold tool, the mandrel enclosed in an air tight layer that includes a vent. Fiber reinforcement material is placed around the mandrel within the mold tool and the membrane is sealed at least partly around the fiber reinforcement material and mandrel. The mold tool is closed with the vent line from the mandrel extending through the sealed membrane to outside of the mold tool. A vacuum is drawn in the mold tool while the mandrel is vented to outside of the mold tool, and while the vacuum is being drawn, resin is infused into the mold tool around the mandrel such that the resin is drawn towards the membrane.

Method for manufacturing a fiber reinforced polymer composite beam, particularly a spar beam for a wind turbine rotor blade

A spar assembly for a rotor blade including a beam structure extending between a closed first end and a second end configured for coupling within a shell of the rotor blade. The beam structure includes a contacting portion extending in a span-wise direction from the second end, a joint portion extending in the span-wise direction from the first end toward the contacting portion, and a transition region between the contacting portion and the joint portion. The contacting portion includes one or more contoured surfaces oriented toward at least one of an internal surface of a pressure or suction side of the rotor blade and configured to follow a contour of one of the pressure or suction side of the rotor blade. The joint portion includes one or more linear surfaces oriented in the same direction as the contoured surface(s). The transition region transitions the contoured surface(s) to the linear surface(s).

Beam structure for a segmented rotor blade having a transitioning shape

A wind turbine composite laminate component and method for producing it is disclosed as initially assembling a laminated structure having at least two reinforced layers and a plurality of interleaf layers positioned adjacent to one of the at least two reinforced layers. Then placing the laminated structure into a mold where resin is sequentially and independently transferred into each of the plurality of interleaf layers. Then curing the transferred resin in the laminated structure to form a composite laminate component having the at least two reinforced layers, the plurality of interleaf layers, and cured resin.

Enhanced through-thickness resin infusion for a wind turbine composite laminate

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.

Methods of manufacturing rotor blade components for a wind turbine

The present disclosure is directed to a rotor blade assembly for a wind turbine having a first rotor blade segment with a first spar cap segment and a second rotor blade segment with a second spar cap segment. The first and second spar cap segments are arranged together at an interface and are constructed of a composite material. Further, the rotor blade assembly includes a joint assembly at the interface of the first and second spar cap segments. The joint assembly is constructed of a first metal joint secured to the first spar cap segment and a second metal joint secured to second spar cap segment. Moreover, the first and second metal joints are welded together at a weld area.

Segmented wind turbine rotor blade with welded joint

Embodiments of a shearography system may include light sources configured to produce beams of light to illuminate a test area. Each of the beams of light may include a different wavelength. A camera may be configured to obtain intensity information corresponding to reflections of the lights off of the test area. An optical shearing device may be disposed in an optical path between the light sources and the camera and the optical shearing device may be configured to provide a shearing angle.

Spatial phase-shift shearography system for non-destructive testing and strain measurement

A method of in-mold coating utilizing an injection molding machine oriented to a horizontal parting line. At the beginning of the cycle the mold opens and a charge of liquid coating solution is deposited onto the lower mold insert. A ophthalmic wafer is deposited on the coating to spread it across the insert surface. The mold is closed and a pre-cure phase elapses before the thermoplastic resin is injected into the mold cavity above the wafer. The process provides coated and functionally enhanced lenses upon ejection from the molding machine.

Injection molding a lens onto a coated ophthalmic wafer

A method for in-mold coating of an injection molded thermoplastic lens that resides in an injection molding machine oriented to a horizontal parting line. An optical lens is initially formed by injecting molten thermoplastic resin into an edge-gated lens-forming cavity held closed under a primary clamp force. The mold is opened at a time when the lens is rigid enough to retain its shape. An unpressurized full metered charge of coating is applied onto the center of the lens. The coating is co-molded by ramping up the clamp force from zero to a secondary clamp force less than the primary clamp force to compress the coating into a uniformly thick, fringe-free layer.

Method for coating an ophthalmic lens within an injection molding machine

A method and coating used to prepare a photochromically-enabled bifocal ophthalmic lens. The method and equipment includes injection molding a single vision lens, for example, from polycarbonate. The clamp opens vertically and the top insert is exchanged for a bifocal mold having a base curve similar to the single vision lens. The thermoset coating includes compounds from several acrylate classes, and is applied to the single vision lens. The coating may include a photochromic dye. The coating is also formulated to receive a photochromic solution through an imbibition process.

Method for adding a thermoset overmold layer to a lens within a mold

A numerical method operating within a processor-based environment for predicting the fill pattern and coating pressure distribution for a substrate in a computer simulation of an in-mold coating flow within a two-dimensional flow domain having a plurality of possible inlet nodes for injection, which includes the steps of initializing pressure and thickness change of the substrate for at least one of the inlet nodes, determining which of the inlet nodes are newly filled nodes and new flow front nodes, calculating pressure for the newly filled nodes; updating thickness and coating volume of the substrate, checking if pressure and time step have converged, and updating pressure and time step and returning to the pressure calculation step if pressure and time step calculations have not converged, and determining whether the substrate is filled, and updating filling time and returning to the determining step if the substrate is not filled.

Growing community of inventors

Simpsonville, SC, United States of America

Xu Chen