Methods for Manufacturing Spar Caps for Wind Turbine Rotor Blades Using Thermoplastic-Based Composite Plates

Abstract

In one aspect, a method for manufacturing a spar cap for a wind turbine rotor blade may generally include stacking a plurality of plates together to form a plate assembly, wherein each of the plates is formed from a fiber-reinforced composite including a plurality of fibers surrounded by a thermoplastic resin material. The method may also include positioning the plate assembly relative to a mold defining a mold surface, wherein the mold surface is shaped so as to correspond to at least one blade parameter of the wind turbine rotor blade. In addition, the method may include applying pressure to the plate assembly via the mold such that at least a portion of the plate assembly conforms to the shape of the mold surface.

1 - 20 . (canceled) 
     
     
         21 . A method for manufacturing a spar cap for a wind turbine rotor blade, the method comprising:
 stacking a first pultruded plate on top of a second pultruded plate, each of the first and second pultruded plates being formed from a fiber-reinforced composite including a plurality of fibers surrounded by a thermoplastic resin material;   transporting the first and second pultruded plates past a heated roller to heat the thermoplastic resin material of the first and second pultruded plates; and   pressing the first and second pultruded plates together such that the thermoplastic resin material of the first pultruded plate is welded to the thermoplastic resin material of the second pultruded plate to form a first plate assembly.   
     
     
         22 . The method of  claim 21 , further comprising assembling a third pultruded plate relative to the first plate assembly, the third pultruded plate being formed from a fiber-reinforced composite including a plurality of fibers surrounded by a thermoplastic resin material. 
     
     
         23 . The method of  claim 21 , further comprising:
 transporting the first plate assembly and the third pultruded plate past the heated roller to heat the thermoplastic resin material contained within the first plate assembly and the third pultruded plate; and   pressing the first plate assembly and the third pultruded plate together such that the thermoplastic resin material of the first plate assembly is welded to the thermoplastic resin material of the third pultruded plate to form a second plate assembly.   
     
     
         24 . The method of  claim 21 , wherein pressing the first and second pultruded plates together comprises applying pressure to the first and second pultruded plates via the heated roller. 
     
     
         25 . The method of  claim 21 , wherein the heated roller comprises a first heated roller and further comprising a second heated roller. 
     
     
         26 . The method of  claim 25 , wherein transporting the first and second pultruded plates past the heated roller comprises transporting the first and second pultruded plates past the first and second heated rollers to heat the thermoplastic resin material of the first and second pultruded plates. 
     
     
         27 . The method of  claim 26 , wherein pressing the first and second pultruded plates together comprises compressing the first and second pultruded plates between the first and second heated rollers. 
     
     
         28 . The method of  claim 21 , wherein the first plate assembly corresponds to the spar cap, further comprising installing the first plate assembly within the wind turbine rotor blade. 
     
     
         29 . The method of  claim 21 , further comprising positioning an additional layer of thermoplastic resin material between the first and second pultruded plates. 
     
     
         30 . A system for manufacturing a spar cap for a wind turbine rotor blade, the system comprising:
 a first pultruded plate stacked on top of a second pultruded plate, each of the first and second pultruded plates being formed from a fiber-reinforced composite including a plurality of fibers surrounded by a thermoplastic resin material; and   a heated roller configured to heat the thermoplastic resin material of the first and second pultruded plates as the first and second pultruded plates are transported past the heated roller, the heated roller being further configured to press the first and second pultruded plates together such that the thermoplastic resin material of the first pultruded plate is welded to the thermoplastic resin material of the second pultruded plate to form a first plate assembly.   
     
     
         31 . The system of  claim 30 , wherein the heated roller comprises a roller and a heat source configured to heat the roller to a specified temperature. 
     
     
         32 . The system of  claim 30 , wherein the heated roller is configured to compress the first and second pultruded plates against a support surface. 
     
     
         33 . The system of  claim 30 , wherein the heated roller comprises a first heated roller, further comprising a second heated roller, the first and second heated rollers being configured to compress the first and second pultruded plates as the first and second pultruded plates are transported between the first and second heated rollers. 
     
     
         34 . The system of  claim 30 , further comprising an additional layer of thermoplastic resin material positioned between the first and second pultruded plates.