Multiple material combinations for printed reinforcement structures of rotor blades

Abstract

Rotor blade panels, along with methods of their formation, are provided. The rotor blade panel may include one or more fiber-reinforced outer skins having an inner surface; and, a plurality of reinforcement structures on the inner surface of the one or more fiber-reinforced outer skins, where the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited. The reinforcement structure includes, at least, a first composition and a second composition, with the first composition being different than the second composition.

What is claimed is: 
     
         1 . A rotor blade shell of a wind turbine blade, comprising:
 one or more thermoformed fiber-reinforced outer skins having an inner surface; and   at least one three-dimensional (3-D) reinforcement grid structure formed onto the inner surface of the one or more thermoformed fiber-reinforced outer skins via additive manufacturing, the at least one 3-D reinforcement grid structure bonding to the one or more thermoformed fiber-reinforced outer skins as the at least one 3-D reinforcement grid structure is being printed and deposited onto the inner surface,   wherein the at least one 3-D reinforcement grid structure is constructed of, at least, a first composition and a second composition, the at least one 3-D reinforcement grid structure comprising discontinuous fibers, and   wherein the first composition is different than the second composition.   
     
     
         2 . The rotor blade shell of  claim 1 , wherein the at least one 3-D reinforcement grid structure is formed of a plurality of rib structures. 
     
     
         3 . The rotor blade shell of  claim 2 , wherein the plurality of rib structures comprises, at least, a first rib structure comprising the first composition and a second rib structure comprising the second composition. 
     
     
         4 . The rotor blade shell of  claim 2 , wherein at least one of the plurality of rib members is constructed of a prefabricated member comprising the first composition positioned on the inner surface with the second composition extruded over the prefabricated member in a melted state such that, upon solidification, at least a portion of the second composition covers and contacts the prefabricated member comprising the first composition. 
     
     
         5 . The rotor blade shell of  claim 2 , wherein at least one of the plurality of rib members is constructed of a first layer of thermoplastic material additively manufactured directly onto the inner surface and defining an opening with a prefabricated member being positioned into the opening of the first layer of thermoplastic material such that the prefabricated member is anchored within the opening. 
     
     
         6 . The rotor blade shell of  claim 1 , wherein each of the first composition and the second composition comprises a matrix loaded with a constituent, with a variation of a loading concentration being a difference between the first composition and the second composition. 
     
     
         7 . The rotor blade shell of  claim 6 , wherein the matrix of the first composition and the second composition comprises a thermoplastic material. 
     
     
         8 . The rotor blade shell of  claim 6 , wherein the constituent comprises one or more of fibers, particles, microspheres, or a combination thereof. 
     
     
         9 . The rotor blade shell of  claim 1 , wherein each of the first composition and the second composition comprises a matrix loaded with a constituent, with a variation of a constituent composition is a difference between the first composition and the second composition. 
     
     
         10 . The rotor blade shell of  claim 1 , wherein the first composition comprises a first matrix loaded with first fibers having a first fiber aspect ratio and the second composition comprises a second matrix loaded with second fibers having a second fiber aspect ratio. 
     
     
         11 . The rotor blade shell of  claim 10 , wherein the first aspect ratio is different than the second aspect ratio. 
     
     
         12 . The rotor blade shell of  claim 10 , wherein the first fibers have a different composition than the second fibers. 
     
     
         13 . The rotor blade shell of  claim 1 , wherein the first composition comprises one or more fibers selected from the group consisting of glass fibers, carbon fibers, polymer fibers, wood fibers, bamboo fibers, ceramic fibers, nanofibers, metal fibers, or similar or combinations thereof. 
     
     
         14 . The rotor blade shell of  claim 1 , wherein the second composition includes one or more fibers selected from the group consisting of glass fibers, carbon fibers, polymer fibers, wood fibers, bamboo fibers, ceramic fibers, nanofibers, metal fibers, or similar or combinations thereof. 
     
     
         15 . The rotor blade shell of  claim 1 , wherein the second composition comprises one or more fibers that are different than fibers from the first composition. 
     
     
         16 . The rotor blade shell of  claim 1 , wherein the first composition comprises a first thermoplastic material, and wherein the second composition comprises a second thermoplastic material that is different in composition than the first thermoplastic material. 
     
     
         17 . The rotor blade shell of  claim 1 , wherein the first composition comprises a thermoplastic foam. 
     
     
         18 . The rotor blade shell of  claim 1 , wherein the first composition has a first density that is less than a second density of the second composition. 
     
     
         19 . A rotor blade shell of a wind turbine blade, comprising:
 one or more thermoformed fiber-reinforced outer skins having an inner surface; and   at least one three-dimensional (3-D) reinforcement grid structure formed onto the inner surface of the one or more thermoformed fiber-reinforced outer skins via additive manufacturing, the at least one 3-D reinforcement grid structure deposited onto the inner surface and bonding to the one or more thermoformed fiber-reinforced outer skins before the one or more fiber-reinforced outer skins have completely cooled,   wherein the at least one 3-D reinforcement grid structure is constructed of, at least, a first composition and a second composition, the at least one 3-D reinforcement grid structure comprising discontinuous fibers with aspect ratios ranging from 4 to 2000,   wherein the first composition is different than the second composition; and   wherein each of the first composition and the second composition comprises a matrix loaded with a constituent, with a variation of a loading concentration being a difference between the first composition and the second composition.   
     
     
         20 . The rotor blade shell of  claim 6 , wherein the matrix of the first composition and the second composition comprises a thermoplastic material.