Optimized Structural Support for Wind Turbine Blades

Publication ID: 24-11857851_0007_PTD
Published: October 28, 2025
Category:New Applications & Use Cases

Legal Citation

pr1or.art Inc., “Optimized Structural Support for Wind Turbine Blades,” Published Technical Disclosure No. 24-11857851_0007_PTD, Published October 28, 2025, available at https://archive.pr1or.art/24-11857851_0007_PTD
This technical disclosure describes improvements that would be readily apparent to a Person Having Ordinary Skill In The Art (PHOSITA) when considered in combination with the foundational architecture disclosed in U.S. Patent No. 11,857,851.

Summary of the Inventive Concept

The inventive concept applies the core technology of the original patent to optimize structural support in wind turbine blades, reducing fatigue, vibration, and increasing stability.

Background and Problem Solved

Traditional wind turbine blades often suffer from structural weaknesses, leading to reduced efficiency and lifespan. The original patent's innovative support structures for golf club heads can be adapted to address these limitations, providing a novel solution for the wind energy industry.

Detailed Description of the Inventive Concept

The inventive concept utilizes a network of slender connected elements to provide improved curvature and rate of change of curvature, withstanding high wind loads and reducing fatigue. The elements are designed using computer-aided design software and manufactured using additive techniques, ensuring optimized structural support. The system can be integrated with sensors and processing units to monitor and optimize the structural integrity of wind turbine blades.

Novelty and Inventive Step

The new claims introduce a novel application of the original patent's technology to the wind energy industry, providing an inventive step in optimizing structural support for wind turbine blades. The specific combination of curvature, rate of change of curvature, and additive manufacturing techniques constitutes a non-obvious innovation.

Alternative Embodiments and Variations

Alternative embodiments may include variations in the design of the support elements, such as different geometries or materials. The inventive concept could also be applied to other industries, such as aerospace or construction, where optimized structural support is critical.

Potential Commercial Applications and Market

The inventive concept has significant commercial potential in the wind energy industry, enabling the development of more efficient and durable wind turbine blades. The target market includes wind turbine manufacturers, wind farm operators, and renewable energy companies.

CPC Classifications

SectionClassGroup
A A63 A63B53/0487
A A63 A63B53/0408
B B22 B22F10/14
B B22 B22F10/80
B B33 B33Y10/00
A A63 A63B53/0412

Field of Art

Advanced Manufacturing and Structural Design, focusing on additive manufacturing techniques for complex geometrical components in sports equipment and industrial applications

Person of Ordinary Skill (PHOSITA) Profile

A mechanical engineer with expertise in computer-aided design, additive manufacturing, and structural optimization, possessing knowledge of binder jet 3D printing and advanced geometric modeling techniques

Obviousness Rationale

A PHOSITA would recognize that the core manufacturing methodology and structural support principles from the golf club head patent can be readily translated to wind turbine blade design by applying known additive manufacturing techniques and structural optimization principles. The fundamental approach of creating complex, curved support structures with smooth geometric transitions is directly transferable between different mechanical systems. The technical problem of reducing structural fatigue through optimized support geometry is a common engineering challenge across multiple domains.

Obvious Combinations & Variations

Source Patent Element
Binder jet manufacturing method for creating complex geometric support structures in golf club heads
PTD Variation
Applying identical binder jet manufacturing process to create support structures for wind turbine blades
Obviousness Reasoning
Predictable extension of known manufacturing technique to a structurally analogous mechanical system with similar design requirements
Source Patent Element
Support members extending at specific angles with curved, non-linear geometries
PTD Variation
Implementing similar curved support members extending from leading to trailing edges of wind turbine blades
Obviousness Reasoning
Known design strategy for optimizing structural load distribution through continuous geometric transitions
Source Patent Element
Avoiding sharp corners and implementing smooth geometric transitions
PTD Variation
Designing wind turbine blade support structures with continuously changing cross-sectional shapes
Obviousness Reasoning
Established engineering principle of reducing stress concentrations through smooth geometric morphology
Source Patent Element
Computer-aided design techniques for generating complex structural components
PTD Variation
Using computational modeling to create optimized support structures with integrated sensor monitoring capabilities
Obviousness Reasoning
Logical progression of design methodology by incorporating additional computational optimization and monitoring features
Source Patent Element
Additive manufacturing of structural components with powdered materials
PTD Variation
Extending powder-based manufacturing to create multi-functional support structures with embedded sensing capabilities
Obviousness Reasoning
Predictable technological advancement combining known manufacturing processes with emerging sensor integration techniques
35 U.S.C. § 103 Summary: Based on US Patent 11857851's teachings, the present publication demonstrates that a Person Having Ordinary Skill In The Art would find the disclosed wind turbine blade support structures obvious through straightforward application of known additive manufacturing techniques, geometric optimization principles, and cross-domain structural design strategies. The variations represent predictable engineering solutions utilizing well-established technological approaches in structural component design and manufacturing.

Original Patent Information

Patent NumberUS 11,857,851
TitleSupport structures for golf club heads and methods of manufacturing improved support structures
Assignee(s)Topgolf Callaway Brands Corp.