US 12,320,328 B1
Wind turbine blade made with date palm tree material
Yasser Fouad Ahmed, Riyadh (SA)
Assigned to KING SAUD UNIVERSITY, Riyadh (SA)
Filed by KING SAUD UNIVERSITY, Riyadh (SA)
Filed on Dec. 5, 2024, as Appl. No. 18/969,860.
Int. Cl. F03D 1/06 (2006.01)
CPC F03D 1/0675 (2013.01) [F05B 2220/30 (2013.01); F05B 2230/23 (2013.01); F05B 2240/21 (2013.01); F05B 2240/30 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A method of manufacturing a wind turbine blade, the method comprising:
forming a first shell of a wind turbine blade, the first shell having a first exterior side surface, a first interior side surface, and a first mating side surface connecting the first interior and first exterior side surfaces to one another;
forming a second shell of a wind turbine blade, the second shell having a second exterior side surface, a second interior side surface, and a second mating side surface connecting the second interior and second exterior side surfaces to one another; and
connecting the first and second mating side surfaces to one another to form the wind turbine blade,
wherein the first and second shells include date palm tree material and epoxy,
wherein the forming of the first shell comprises:
obtaining a first mold, the first mold defining a shape of the first shell;
forming a first layer of date palm tree material in the first mold, the first layer of date palm tree material defining the first exterior side surface of the first shell or being proximate to the first exterior side surface of the first shell;
forming a second layer of epoxy on the first layer of date palm tree material;
forming a third layer of date palm tree material on the second layer of epoxy;
forming a fourth layer of epoxy on the third layer of date palm tree material; and
forming a fifth layer of date palm tree material on the fourth layer of epoxy, the fifth layer of date palm tree material defining the first interior side surface of the first shell or being proximate to the first interior side surface of the first shell and distal to the first exterior side surface of the first shell,
wherein a weight ratio of date palm tree material included in the first layer of date palm tree material and epoxy included in the second layer of epoxy ranges from about 50:100 to about 150:150.
 
17. A method of manufacturing a wind turbine blade, the method comprising:
forming a first shell of a wind turbine blade, the first shell having a first exterior side surface, a first interior side surface, and a first mating side surface connecting the first interior and first exterior side surfaces to one another;
forming a second shell of a wind turbine blade, the second shell having a second exterior side surface, a second interior side surface, and a second mating side surface connecting the second interior and second exterior side surfaces to one another; and
connecting the first and second mating side surfaces to one another to form the wind turbine blade,
wherein the first and second shells include date palm tree material and epoxy,
wherein the forming of the first shell comprises:
obtaining a first mold, the first mold defining a shape of the first shell;
forming a first layer of date palm tree material in the first mold, the first layer of date palm tree material defining the first exterior side surface of the first shell or being proximate to the first exterior side surface of the first shell;
forming a second layer of epoxy on the first layer of date palm tree material;
forming a third layer of date palm tree material on the second layer of epoxy;
forming a fourth layer of epoxy on the third layer of date palm tree material; and
forming a fifth layer of date palm tree material on the fourth layer of epoxy, the fifth layer of date palm tree material defining the first interior side surface of the first shell or being proximate to the first interior side surface of the first shell and distal to the first exterior side surface of the first shell,
wherein a weight ratio of date palm tree material included in the first layer of date palm tree material and epoxy included in the second layer of epoxy ranges from about 50:100 to about 150:150, and
wherein a weight ratio of resin to hardener in the second layer of epoxy is 2:1, 3:2 or 5:3.
 
18. A method of manufacturing a wind turbine blade, the method comprising:
forming a first shell of a wind turbine blade, the first shell having a first exterior side surface, a first interior side surface, and a first mating side surface connecting the first interior and first exterior side surfaces to one another;
forming a second shell of a wind turbine blade, the second shell having a second exterior side surface, a second interior side surface, and a second mating side surface connecting the second interior and second exterior side surfaces to one another; and
connecting the first and second mating side surfaces to one another to form the wind turbine blade,
wherein the first and second shells include date palm tree material and epoxy,
wherein the forming of the first shell comprises:
obtaining a first mold, the first mold defining a shape of the first shell;
forming a first layer of date palm tree material in the first mold, the first layer of date palm tree material defining the first exterior side surface of the first shell or being proximate to the first exterior side surface of the first shell;
forming a second layer of epoxy on the first layer of date palm tree material;
forming a third layer of date palm tree material on the second layer of epoxy;
forming a fourth layer of epoxy on the third layer of date palm tree material; and
forming a fifth layer of date palm tree material on the fourth layer of epoxy, the fifth layer of date palm tree material defining the first interior side surface of the first shell or being proximate to the first interior side surface of the first shell and distal to the first exterior side surface of the first shell,
wherein a weight ratio of date palm tree material included in the first layer of date palm tree material and epoxy included in the second layer of epoxy ranges from about 50:100 to about 150:150,
wherein a weight ratio of resin to hardener in the second layer of epoxy is 2:1, 3:2 or 5:3, and
wherein the forming of the first layer of date palm tree material in the first mold includes depositing from 50 g of date palm leaflets per m2 of the first mold to 150 g of date palm leaflets per m2 of the first mold.