Organic conductive elements for deicing and lightning protection of a wind turbine rotor blade

• US 10,648,456 B2
• Filed: 10/21/2016
• Issued: 05/12/2020
• Est. Priority Date: 10/21/2016
• Status: Active Grant

• Current Assignee: GE Infrastructure Technology, LLC (GE Vernova, Inc.)
• Original Assignee: General Electric Company
• Inventors: Shain, Eric Michael, Patel, Jignesh, Hardison, Richard, Riahi, Amir
• Primary Examiner(s): White, Dwayne J
• Assistant Examiner(s): Fisher, Wesley L E
• Application Number:
  US15/299,508
• Publication Number:
  US 20180112649A1
• Time in Patent Office: 1,299 Days
• CPC Class Codes: F03D 1/0675 of the blades
• CPC Class Codes: F03D 80/30 Lightning protection
• CPC Class Codes: F03D 80/40 Ice detection; De-icing means
• CPC Class Codes: F05B 2280/2006 Carbon, e.g. graphite
• CPC Class Codes: F05B 2280/40 Organic materials
• CPC Class Codes: F05B 2280/4011 Organic materials not otherwise provided for
• CPC Class Codes: Y02E 10/72 Wind turbines with rotation axis in wind direction

Abstract

The present disclosure is directed to a rotor blade assembly for a wind turbine. The rotor blade assembly includes a rotor blade having a body shell with a pressure side, a suction side, a leading edge, and a trailing edge each extending between a root portion and a tip portion. Further, the rotor blade assembly includes a protection system configured to protect the rotor blade from ice accumulation or a lightning strike. The protection system includes at least one organic conductive element configured within the rotor blade. The protection system also includes a conductor source electrically or thermally coupled to the organic conductive element. Thus, the conductor source is configured to heat the organic conductive element so as to prevent ice from accumulating on the rotor blade or to provide a conductive path for the lightning strike.

Claims

1. A rotor blade assembly for a wind turbine, the rotor blade assembly comprising:

a rotor blade having a body shell comprising a pressure side, a suction side, a leading edge, and a trailing edge each extending between a root portion and a tip portion, the body shell being constructed of one or more foam materials; and

,

a protection system configured to protect the rotor blade from ice accumulation or a lightning strike, the protection system comprising;

at least one organic conductive foam core embedded at or near the leading edge of the rotor blade in place of the one or more foam materials of the body shell, the at least one organic conductive foam core comprising a carbon-based foam core; and

,

a conductor source coupled to the at least one organic conductive foam core, the conductor source comprising at least a conductive cable infused into or configured adjacent to a leading edge bond cap of the rotor blade,

wherein the conductor source is configured to heat the organic conductive foam core so as to prevent ice from accumulating on the rotor blade or to provide a conductive path for the lightning strike.

2. The rotor blade assembly of claim 1, further comprising an additional organic conductive foam core in at least one of, a spar cap of the rotor blade, or a shear web of the rotor blade.

3. The rotor blade assembly of claim 1, wherein the carbon-based foam core comprises at least one of additives, binders, fillers, or one or more structural members.

4. The rotor blade assembly of claim 1, wherein the carbon-based foam core is free of additives, binders, or fillers.

5. The rotor blade assembly of claim 2, wherein the conductor source further comprises at least one of an electrical heater, one or more electrical resistors, forced air, an induction heater, a conductive heater, or a convection heater.

6. The rotor blade assembly of claim 1, wherein the rotor blade is constructed of a plurality of rotor blade segments, each of the rotor blade segments comprising a portion of the organic conductive foam core.

7. A method for protecting a rotor blade of a wind turbine from ice accumulation or a lightning strike, the method comprising:

providing a body shell of the rotor blade being constructed of one or more foam materials;

embedding at least one organic conductive foam core at or near the leading edge of the rotor blade between the one or more foam materials, the organic conductive foam core comprising a carbon-based foam core;

connecting a down conductor between a conductive tip portion of the rotor blade and the organic conductive foam core;

during operation of the wind turbine, monitoring a weather-related parameter of the rotor blade; and

,

implementing a protective action when the weather-related parameter indicates the presence of ice or a lightning strike.

8. The method of claim 7, wherein implementing the protective action comprises at least one of heating the at least one organic conductive foam core via the down conductor or providing a conductive path for the lightning strike via the down conductor.

9. The method of claim 7, further comprising providing an additional organic conductive foam core in at least one of a spar cap of the rotor blade or a shear web of the rotor blade.

10. The method of claim 7, wherein the carbon-based foam core comprises at least one of additives, binders, fillers, or one or more structural members.

11. The method of claim 7, wherein the carbon-based foam core is free of additives, binders, or fillers.