Patent Application
20220152964
The present disclosure relates to manufacture of a reinforced shell part of wind turbine blades. More specifically, the present disclosure pertains to the field of manufacturing a reinforced shell part with a pultrusion layer and a preform for an inlay, such as a preform for a first inlay and/or a second inlay.
Wind turbine blades of fibre-reinforced polymer and in particular the aerodynamic shells of wind turbine blades usually comprise a reinforced section comprising pultrusion layer extending in the spanwise direction of the wind turbine blade. During manufacture of the wind turbine blade two half shells are manufactured by laying out glass fibre mats to form a half shell, and carbon fibre mats are laid out on top of the glass fibre mats to form a pultrusion layer. Optionally, an additional base layer of glass fibres forming a base part is laid out on the shell before the pultrusion layer is laid on top of the base part. Afterwards, the layers are infused with a resin, such as polyester or epoxy. Infusion of the fibres may be provided by vacuum assisted resin transfer moulding (VARTM). One of the two halves is then turned upside down and positioned on top of the other of the two halves, and the two halves are adhered together. The blade parts may be positioned on top of each other by turning and repositioning the complete half mould.
During the vacuum assisted resin transfer moulding process fibres may be compressed and cause wrinkles. Especially glass fibres are more prone to compression when they are arranged underneath a pultrusion layer, and the wrinkles most often occur in the glass fibre layers near the edges of the pultrusion layer, as the more compact carbon fibres of the pre-cured pultrusion layer compress less than the underlying glass fibres. Wrinkles are undesirable, as they decrease the stiffness and strength of a wind turbine blade.
There is a need to decrease the occurrence of wrinkles in the shell and/or the base part.
It is an object of the present disclosure to provide an enhanced method for manufacturing a reinforced shell part for a wind turbine blade. It is a further objective of the present disclosure to provide a wind turbine blade comprising a reinforced section which overcomes at least some of the disadvantages of the prior art.
In particular, it is an object of the present invention to provide a method for manufacturing a reinforced shell part for a wind turbine blade and a wind turbine blade comprising a reinforced section without wrinkles in the shell and/or base part of the reinforced section.
The present inventors have found that one or more of the above-identified objects can be addressed by providing a first inlay and a second inlay under the edges of the pultrusion layer of the reinforced section, thereby avoiding compression of the glass fibres of the shell and/or base part near the edges of the pultrusion layer.
Accordingly, in a first aspect, the present invention relates to a method for manufacturing a reinforced shell part for a wind turbine blade, the method comprising providing a shell, such as a shell half, having an inner surface, optionally arranging a plurality of fibre layers on the inner surface of the shell to form a base part of a reinforced section, providing a preform of a first inlay, arranging the preform of the first inlay on the inner surface of the shell and/or on the base part of the reinforced section, providing a preform of a second inlay, arranging the preform of the second inlay on the inner surface of the first shell part and/or on the base part of the reinforced section, arranging at least one pultrusion layer on the preform of the first inlay, on the preform of the second inlay, and on the inner surface of the shell and/or the base part of the reinforced section, wherein the pultrusion layer comprises a plurality of pultruded members grouped together, the pultrusion layer having a proximal edge, a distal edge and two opposing lateral edges, and wherein the pultrusion layer is arranged in a spanwise direction of the blade such that the proximal edge of the pultrusion layer is arranged on the preform of the first inlay and the distal edge of the pultrusion layer is arranged on the preform of the second inlay.
According to a preferred embodiment, the present invention relates to a method for manufacturing a reinforced shell part for a wind turbine blade, the method comprising providing a shell, such as a shell half, having an inner surface, optionally arranging a plurality of fibre layers on the inner surface of the shell to form a base part of a reinforced section, providing a preform of a first inlay, arranging the preform of the first inlay on the inner surface of the shell and/or on the base part of the reinforced section, wherein the top surface of the first inlay is substantially flush with the surrounding inner surface of the shell or with the top surface of the base part of the reinforced section, providing a preform of a second inlay, arranging the preform of the second inlay on the inner surface of the first shell part and/or on the base part of the reinforced section, wherein the top surface of the second inlay is substantially flush with the surrounding inner surface of the shell or with the top surface of the base part of the reinforced section, arranging at least one pultrusion layer on the preform of the first inlay, on the preform of the second inlay, and on the inner surface of the shell and/or the base part of the reinforced section, wherein the pultrusion layer comprises a plurality of pultruded members grouped together, the pultrusion layer having a proximal edge, a distal edge and two opposing lateral edges, and wherein the pultrusion layer is arranged in a spanwise direction of the blade such that the proximal edge of the pultrusion layer is arranged on the preform of the first inlay and the distal edge of the pultrusion layer is arranged on the preform of the second inlay.
According to a preferred embodiment, the present invention relates to a method for manufacturing a reinforced shell part for a wind turbine blade, the method comprising providing a shell, such as a shell half, having an inner surface, optionally arranging a plurality of fibre layers on the inner surface of the shell to form a base part of a reinforced section, providing a preform of a first inlay, arranging the preform of the first inlay on the inner surface of the shell, wherein the top surface of the first inlay is substantially flush with the top surface of the base part of the reinforced section, providing a preform of a second inlay, arranging the preform of the second inlay on the inner surface of the first shell part, wherein the top surface of the second inlay is substantially flush with the top surface of the base part of the reinforced section, arranging at least one pultrusion layer on the preform of the first inlay, on the preform of the second inlay, and on the inner surface of the shell and/or the base part of the reinforced section, wherein the pultrusion layer comprises a plurality of pultruded members grouped together, the pultrusion layer having a proximal edge, a distal edge and two opposing lateral edges, and wherein the pultrusion layer is arranged in a spanwise direction of the blade such that the proximal edge of the pultrusion layer is arranged on the preform of the first inlay and the distal edge of the pultrusion layer is arranged on the preform of the second inlay.
Thus, according to the present invention, a preform may be introduced to the shell or to the base part near the edges of the pultrusion layer during manufacture. The preform may comprise a stack of pre-cured glass fibre mats and has a stiffer property than glass fibre mats of the shell or base part before infusion and may thus remedy occurrences of wrinkles.
The reinforced shell part may be a reinforced shell half, such as a reinforced upwind shell half or a reinforced downwind shell half. Such shell parts usually comprise a reinforced section, such as a spar cap or a main laminate. The shell provided in the method of the present invention may be a shell half, such as an upwind shell half or a downwind shell half. Typically, a shell or shell half comprises an aerodynamic outer surface and an opposing inner surface. In a preferred embodiment, the shell comprises a fibre material infused by resin and subsequently cured, for example forming a fibre laminate. The shell or shell half may optionally comprise a sandwich material. For example, the shell may comprise an outer fibre reinforced layer forming an outer surface and an inner reinforced layer forming an inner surface, the outer fibre reinforced layer and the inner reinforced layer separated by a sandwich material forming a core. The core material may of balsa wood or foam material. Alternatively, part of the shell may comprise fibre reinforced material only, forming the outer surface and the inner surface of the shell. In the method of the present invention, one or more fibre layers may be provided on the inner surface of the shell or shell half to form a base part of a reinforced section, such as a base part of a spar cap.
Providing a shell may comprise providing a shell comprising an outer surface, an inner surface and a sandwich material arranged between the outer surface and the inner surface. Alternatively, providing a shell may comprise providing a shell comprising a fibre reinforced layer and without a sandwich material, such that the fibre reinforced layer forms an outer surface and an inner surface of the shell.
The method of the present invention also comprises providing respective preforms of a first and of a second inlay. Typically, a preform is a shaped arrangement of fibres, such as multiple layers thereof, which has been bound and/or consolidated for later use as part of a fibre lay-up for example in a blade mould. The preforms of the present invention may have a substantially rectangular or cuboid shape. In a preferred embodiment, the preform comprises a fibre material and a binding agent.
The method of the present invention may comprise arranging the preform of the first inlay and the preform of the second inlay on the inner surface of the shell, such as on the inner surface of a shell half. In other embodiments, when the reinforced section is to comprise a base part underneath the pultrusion layer, the preforms of the first and second inlay are arranged on the previously arranged base part of the later reinforced section.
While the pultrusion layer is usually arranged in a substantially spanwise or longitudinal direction of the blade, the first and second preforms/inlays are typically arranged substantially perpendicular to the spanwise direction. Thus, the longest dimension of the preform/inlay usually extends substantially perpendicularly to the spanwise direction.
The method of the present invention also comprises arranging at least one pultrusion layer on the respective preforms of the first and second inlays. The pultrusion layer typically comprises a plurality of pultruded members grouped together. The pultrusion layer has a proximal edge, which is usually closest to the root end of the final blade, and a distal edge, which is usually closest to the tip end of the final blade, and two opposing lateral edges. The pultrusion layer is arranged in a spanwise direction of the blade such that the proximal edge of the pultrusion layer is arranged on the preform of the first inlay and the distal edge of the pultrusion layer is arranged on the preform of the second inlay.
In a preferred embodiment, the first and second preforms/inlays are received in respective recesses provided in the inner shell surface or in the base part of the reinforced section. Thus, the top surface of the preform/inlay is preferably substantially flush with the surrounding inner surface of the shell or with the top surface of the base part of the reinforced section.
In another aspect, the present invention relates to a wind turbine blade having a profiled contour including a pressure side and a suction side, and a leading edge and a trailing edge with a chord having a chord length extending therebetween. The wind turbine blade extends in a spanwise direction between a root end and a tip end. The wind turbine blade comprises a shell part, such as a downwind shell half and an upwind shell half, a reinforced section, such as a spar cap or a main laminate, extending along at least part of the shell part in a spanwise direction of the blade.
The reinforced section of the blade comprises a plurality of pultruded members grouped together to form at least one pultrusion layer extending in a spanwise direction of the blade. The pultrusion layer has a proximal edge closest to the root end of the blade, a distal edge closest to the tip end of the blade and two opposing lateral edges extending in a spanwise direction of the blade.
The wind turbine blade of the present invention preferably comprises a first inlay arranged underneath part of the pultrusion layer such that it extends along the entire proximal edge of the pultrusion layer, and a second inlay arranged underneath part of the pultrusion layer such that it extends along the entire distal edge of the pultrusion layer.
According to another preferred embodiment, the present invention relates to a wind turbine blade having a profiled contour including a pressure side and a suction side, and a leading edge and a trailing edge with a chord having a chord length extending therebetween. The wind turbine blade extends in a spanwise direction between a root end and a tip end. The wind turbine blade comprises a shell part, such as a downwind shell half and an upwind shell half, a reinforced section, such as a spar cap or a main laminate, extending along at least part of the shell part in a spanwise direction of the blade.
The reinforced section of the blade comprises a plurality of pultruded members grouped together to form at least one pultrusion layer extending in a spanwise direction of the blade. The pultrusion layer has a proximal edge closest to the root end of the blade, a distal edge closest to the tip end of the blade and two opposing lateral edges extending in a spanwise direction of the blade.
The wind turbine blade of the present invention preferably comprises a first inlay arranged underneath part of the pultrusion layer such that it extends along the entire proximal edge of the pultrusion layer, and wherein the top surface of the first inlay is substantially flush with the surrounding inner surface of the shell or with the top surface of the base part of the reinforced section, and a second inlay arranged underneath part of the pultrusion layer such that it extends along the entire distal edge of the pultrusion layer, and wherein the top surface of the second inlay is substantially flush with the surrounding inner surface of the shell or with the top surface of the base part of the reinforced section.
According to another preferred embodiment, the present invention relates to a wind turbine blade having a profiled contour including a pressure side and a suction side, and a leading edge and a trailing edge with a chord having a chord length extending therebetween. The wind turbine blade extends in a spanwise direction between a root end and a tip end. The wind turbine blade comprises a shell part, such as a downwind shell half and an upwind shell half, a reinforced section, such as a spar cap or a main laminate, extending along at least part of the shell part in a spanwise direction of the blade.
The reinforced section of the blade comprises a plurality of pultruded members grouped together to form at least one pultrusion layer extending in a spanwise direction of the blade. The pultrusion layer has a proximal edge closest to the root end of the blade, a distal edge closest to the tip end of the blade and two opposing lateral edges extending in a spanwise direction of the blade.
The wind turbine blade of the present invention preferably comprises a first inlay arranged underneath part of the pultrusion layer such that it extends along the entire proximal edge of the pultrusion layer, and wherein the top surface of the first inlay is substantially flush with the top surface of the base part of the reinforced section, and a second inlay arranged underneath part of the pultrusion layer such that it extends along the entire distal edge of the pultrusion layer, and wherein the top surface of the second inlay is substantially flush with the top surface of the base part of the reinforced section.
It is an advantage of the present disclosure that wrinkles in the shell and/or base part can be avoided. It is a further advantage of the present disclosure that the preform has the same or similar material properties as the shell and/or base part and that the material is light weight.
The preform of the first inlay and/or second inlay may extend in a substantially chordwise direction. The preform of the first and/or second inlay may comprise a fibre material. The preform of the first inlay may comprise sheets of fibres, such as sheets of fibres or fibre mats or glass fibre mats. The preform of the first inlay may comprise a stack of sheets, such as a stack of sheets of glass fibres. Alternatively, the preform of the first inlay may comprise glass fibres, carbon fibres, aramid fibres, basalt fibres, natural fibres or mixtures thereof. The preform of the first inlay may comprise a stack of sheets of glass fibres comprising a binding agent.
It is an advantage of the present disclosure that preforms are provided. Preforms may be manufactured offline, which may reduce the in-mould manufacturing time of a wind turbine blade. In addition, manufacturing the preforms offline may provide preforms of higher quality and uniformity.
In a preferred embodiment, the preform/inlay of the present invention may have a chamfered edge. The distal ends of each sheet of fibre of the preform/inlay may be chamfered. The proximal ends of each sheet of fibre of the preform/inlay may be chamfered.
The thickness of the preform of the first inlay may taper towards the distal edge. The thickness of the preform of the first inlay may taper towards the proximal edge. The thickness of the preform of the first inlay may taper towards the distal edge and the proximal edge in the same direction. Alternatively, the thickness of the preform of the first inlay may taper towards the distal edge and the proximal edge in the opposite direction.
The preform of the second inlay may extend in a substantially chordwise direction. The preform of the second inlay may comprise a fibre material. The preform of the second inlay may comprise sheets of fibres, such as sheets of fibres or fibre mats or glass fibre mats. The preform of the second inlay may comprise a stack of sheets, such as a stack of sheets of glass fibres. Alternatively, the preform of the second inlay may comprise glass fibres, carbon fibres, aramid fibres, basalt fibres, natural fibres or mixtures thereof. The preform of the second inlay may comprise a stack of sheets of glass fibres comprising a binding agent. The distal ends of each sheet of fibre may be chamfered. The proximal ends of each sheet of fibre may be chamfered.
The thickness of the preform of the second inlay may taper towards the distal edge. The thickness of the preform of the second inlay may taper towards the proximal edge. The thickness of the preform of the second inlay may taper towards the distal edge and the proximal edge in the same direction. Alternatively, the thickness of the preform of the second inlay may taper towards the distal edge and the proximal edge in the opposite direction.
The preform of the third inlay may extend in a substantially chordwise direction. The preform of the third inlay may comprise a fibre material. The preform of the third inlay may comprise sheets of fibres, such as sheets of fibres or fibre mats or glass fibre mats. The preform of the third inlay may comprise a stack of sheets, such as a stack of sheets of glass fibres. Alternatively, the preform of the third inlay may comprise glass fibres, carbon fibres, aramid fibres, basalt fibres, natural fibres or mixtures thereof. The preform of the third inlay may comprise a stack of sheets of glass fibres comprising a binding agent. The distal ends of each sheet of fibre may be chamfered. The proximal ends of each sheet of fibre may be chamfered.
The thickness of the preform of the third inlay may taper towards the distal edge. The thickness of the preform of the third inlay may taper towards the proximal edge. The thickness of the preform of the third inlay may taper towards the distal edge and the proximal edge in the same direction. Alternatively, the thickness of the preform of the third inlay may taper towards the distal edge and the proximal edge in the opposite direction.
The preform of the fourth inlay may extend in a substantially chordwise direction. The preform of the fourth inlay may comprise a fibre material. The preform of the fourth inlay may comprise sheets of fibres, such as sheets of fibres or fibre mats or glass fibre mats.
The preform of the fourth inlay may comprise a stack of sheets, such as a stack of sheets of glass fibres. Alternatively, the preform of the fourth inlay may comprise glass fibres, carbon fibres, aramid fibres, basalt fibres, natural fibres or mixtures thereof. The preform of the fourth inlay may comprise a stack of sheets of glass fibres comprising a binding agent. The distal ends of each sheet of fibre may be chamfered. The proximal ends of each sheet of fibre may be chamfered.
The thickness of the preform of the fourth inlay may taper towards the distal edge. The thickness of the preform of the fourth inlay may taper towards the proximal edge. The thickness of the preform of the fourth inlay may taper towards the distal edge and the proximal edge in the same direction. Alternatively, the thickness of the preform of the fourth inlay may taper towards the distal edge and the proximal edge in the opposite direction.
The sheets of fibres stacked to form a preform of an inlay may be prefabricated with a binding agent. Alternatively, the sheets may be dry fabric. Alternatively, the sheets may be a prepreg. The binding agent may be a thermoplastic binding agent. The binding agent may be a binding powder, such as a thermoplastic binding powder.
Stacking the sheets may comprise applying a binding agent to the fabric. Stacking the sheets may comprise stacking sheets with a desired size to form a desired size of the preform. Stacking sheets may comprise stacking sheets and cutting out the preform of the desired size. Stacking the sheets may comprise arranging the sheets in a mould.
In a preferred embodiment, the preforms of the present invention comprise glass fibres. Alternatively, or in addition, the preforms may comprise carbon fibres. In some embodiments, the preforms may comprise glass fibres, carbon fibres, aramid fibres, basalt fibres, natural fibres or mixtures thereof. The binding agent may present in an amount of 0.1-15 wt % relative to the weight of the fibre material of the preform.
Preferably, the binding agent is present in an amount of 0.5-10 wt %, preferably 0.5-5 wt %, more preferably 0.5-3.5 wt %, relative to the weight of the fibre material. The binding agent may also comprise two or more different substances, as long as the total binding agent is present in an amount of 0.1 - 15 wt % relative to the weight of the fibres. The mixture between fibres and binding agent is such that at least 75%, more preferably at least 90%, most preferably at least 95% of the surface of the fibre sheets is contacted with the binding agent.
The sheets may be consolidated or precured by e.g. by heating, to attach the sheets to each other, and to form a preform of an inlay. After consolidation the preforms obtain a higher stiffness and strength. Alternatively, the sheets may be infused during the infusion process of the wind turbine blade, to form an inlay. The adhesive of the sheets may be configured to be dissolved by the resin as it is infused, such that the adhesive is replaced by resin during the infusion process.
The preforms may constitute part of the reinforced section, such as a spar cap or main laminate, of the wind turbine blade.
In a preferred embodiment, each preform/inlay has a length of 20-100 cm, a width of 30-150 cm and a thickness of 0.5-10 mm. The pultrusion layer typically has a length of 40-80 m, a width of 20-100 cm and a thickness of 5-80 mm. The base part typically has a thickness of 0.5-30 mm, such as 4-30 mm.
Providing a preform of a first inlay may comprise pre-curing the preform of the first inlay.
Providing a preform of a second inlay may comprise pre-curing the preform of the second inlay.
The shell may comprise a root end and a tip end, and the preform of the first inlay may be arranged closer to the root end of the shell than the preform of the second inlay.
The pultrusion layer may be arranged such that its proximal edge is closer to the root end of the shell than its distal end.
The preform of the first inlay may be arranged such that it extends along the entire proximal edge of the pultrusion layer. The preform of the second inlay may be arranged such that it extends along the entire distal edge of the pultrusion layer.
Each of the preforms may have a proximal edge, a distal edge, and two opposing lateral edges. The preform of the first inlay may be arranged such that its proximal edge is closer to the root end of the shell than the proximal edge of the pultrusion layer. The preform of the second inlay may be arranged such that its distal edge is closer to the tip end of the shell than the distal edge of the pultrusion layer.
The distal edge of the preform of the first inlay may be longer than the proximal edge of the pultrusion layer. The proximal edge of the preform of the second inlay may be longer than the distal edge of the pultrusion layer.
The method may comprise infusing the pultrusion layer, the preform of the first inlay, the preform of the second inlay, and optionally the base part of the reinforced section with a resin to form a reinforced section of the first shell part the wind turbine blade.
The method may comprise manufacturing two reinforced shell parts. The method may comprise joining the two reinforced shell parts to form a wind turbine blade.
A preform of a third inlay may be arranged on top of at least part of the pultrusion layer such that it extends along the entire proximal edge of the pultrusion layer. The preform of the third inlay may extend in a substantially chordwise direction. The preform of the third inlay may be arranged closer to the root end of the shell than the preform of the fourth inlay.
A preform of a fourth inlay is may be arranged on top of at least part of the pultrusion layer such that it extends along the entire distal edge of the pultrusion layer. The preform of the fourth inlay each may extend in a substantially chordwise direction. The preform of the fourth inlay may be arranged closer to the tip end of the shell than the preform of the fourth inlay.
In some embodiments, the edges of the reinforced section are chamfered. In a preferred embodiment, the edges of the preform are chamfered. The fibre layers of the reinforced section may be chamfered at a distal end. The fibre layers of the reinforced section may be chamfered at a proximal end.
A third inlay may be arranged on top of at least part of the pultrusion layer such that it extends along the entire proximal edge of the pultrusion layer. The third inlay may be arranged on top of at least part of the first inlay. The third inlay may be arranged on top of at least part of the shell part. The thickness of the third inlay may taper from
A fourth inlay may be arranged on top of at least part of the pultrusion layer such that it extends along the entire distal edge of the pultrusion layer. The fourth inlay may be arranged on top of at least part of the second inlay. The fourth inlay may be arranged on top of at least part of the shell part. The preform of the third inlay may be arranged closer to the root end of the blade than the preform of the fourth inlay.
It is envisaged that any embodiments or elements as described in connection with any one aspect may be used with any other aspects or embodiments, mutatis mutandis.
Embodiments of the invention will be described in more detail in the following with regard to the accompanying figures. Like reference numerals refer to like elements throughout.
Like elements may, thus, not be described in detail with respect to the description of each figure. The figures show one way of implementing the present invention and are not to be construed as being limiting to other possible embodiments falling within the scope of the attached claim set. In addition, an illustrated embodiment need not have all the aspects or advantages shown. An aspect or an advantage described in conjunction with a particular embodiment is not necessarily limited to that embodiment and can be practiced in any other embodiments even if not so illustrated, or if not so explicitly described.
In the following figure description, the same reference numbers refer to the same elements and may thus not be described in relation to all figures.
The airfoil region 34 (also called the profiled region) has an ideal or almost ideal blade shape with respect to generating lift, whereas the root region 30 due to structural considerations has a substantially circular or elliptical cross-section, which for instance makes it easier and safer to mount the blade 10 to the hub. The diameter (or the chord) of the root region 30 may be constant along the entire root area 30. The transition region 32 has a transitional profile gradually changing from the circular or elliptical shape of the root region 30 to the airfoil profile of the airfoil region 34. The chord length of the transition region 32 typically increases with increasing distance r from the hub. The airfoil region 34 has an airfoil profile with a chord extending between the leading edge 18 and the trailing edge 20 of the blade 10. The width of the chord decreases with increasing distance r from the hub.
A shoulder 40 of the blade 10 is defined as the position, where the blade 10 has its largest chord length. The shoulder 40 is typically provided at the boundary between the transition region 32 and the airfoil region 34.
It should be noted that the chords of different sections of the blade normally do not lie in a common plane, since the blade may be twisted and/or curved (i.e. pre-bent), thus providing the chord plane with a correspondingly twisted and/or curved course, this being most often the case in order to compensate for the local velocity of the blade being dependent on the radius from the hub.
The wind turbine blade 10 comprises a blade shell comprising two blade shell parts, a first blade shell part 24 and a second blade shell part 26, typically made of fibre-reinforced polymer. The first blade shell part 24 is typically a pressure side or upwind blade shell part. The second blade shell part 26 is typically a suction side or downwind blade shell part. The first blade shell part 24 and the second blade shell part 26 are fastened together with adhesive, such as glue, along bond lines or glue joints 28 extending along the trailing edge 20 and the leading edge 18 of the blade 10. Typically, the root ends of the blade shell parts 24, 26 has a semi-circular or semi-oval outer cross-sectional shape.
The wind turbine blade 10 comprises a reinforced section 35. In a preferred embodiment, the reinforced section is an integrated reinforced section. Advantageously, the integrated reinforced section forms at least a part of a spar cap or spar beam of the wind turbine. The wind turbine blade comprises a shell 37 onto which the reinforced section is arranged. The reinforced section 35 may comprise an optional base part (not shown) and a pultrusion layer 44. The base part of the reinforced section may comprise fibres, such as glass fibres. The pultrusion layer 44 extends between the proximal edge 46 and the distal edge 48 in a direction parallel to the longitudinal axis L of the wind turbine blade 10, i.e. in a substantially spanwise direction. The pultrusion layer 44 also comprises two opposing lateral edges 43. The proximal edge 46 of the pultrusion layer is closer to the blade root 16 than the distal edge 48 of the pultrusion layer. The distal edge 48 is closer to the tip 14. The pultrusion layer 44 comprises a plurality of pultruded members 49 grouped together and may comprise fibres, such as glass fibres.
The first shell part 24 comprises a first inlay 50 and a second inlay 60 arranged underneath the pultrusion layer 44. The first inlay 50 and second inlay 60 extend in a substantially chordwise. The first inlay 50 extends in a substantially chordwise direction and comprises a proximal edge 52 and a distal edge 54 and two opposing lateral edges 53. The proximal edge 52 of the first inlay is closer to the blade root 16 than the distal edge 54 of the first inlay. The distal edge 54 of the first inlay is closer to the blade tip 14 than the proximal edge 52 of the first inlay. The first inlay 50 is arranged such that it extends underneath the entire proximal edge 46 of the pultrusion layer 44. The distal edge 54 of the first inlay is longer than the proximal edge 46 of the pultrusion layer. Alternatively, the distal edge 54 of the first inlay and the proximal edge 46 of the pultrusion layer may be the same. By providing an inlay with at least the same width as the pultrusion layer edge, the entire width of the end of the laminate may be supported by the inlay.
The second inlay 60 extends in a substantially chordwise direction and comprises a proximal edge 62 and a distal edge 64 and two opposing lateral edges 63. The proximal edge 62 of the second inlay is closer to the blade root 16 than the distal edge 64 of the second inlay. The distal edge 64 of the second inlay is closer to the blade tip 14 than the proximal edge 62 of the second inlay. The second inlay 60 is arranged such that it extends underneath the entire distal edge 48 of the pultrusion layer. The proximal edge 62 of the second inlay is longer than the distal edge 48 of the pultrusion layer. Alternatively, the proximal edge 62 of the second inlay and the distal edge 48 of the pultrusion layer may be the same.
The first inlay 50 is arranged closer to the blade root 16 than the second inlay 60. The second inlay 60 is arranged closer to the blade tip 14 than the first inlay 50. The pultrusion layer 44 is thus supported by the first inlay 50 and the second inlay 60 at its respective ends, e.g. at its proximal edge 46 and distal edge 48.
The inlays typically have a length LPL of 20-100 cm, a width WPL of 30-150 cm and a thickness of 0.5-10 mm (not shown, see e.g.
The first inlay 50 is arranged underneath the proximal edge 46 of the pultrusion layer and the second inlay 60 is arranged underneath the distal edge 48 of the pultrusion layer. The first inlay 50 and the second inlay 60 are arranged such that the top surface 56 of the first inlay and the top surface 66 of the second inlay are flush with the adjacent inner surface 39a of the first shell part 24. The first inlay 50 and the second inlay 60 comprise sheets of fibre material, such as sheets of glass fibre fabric and are stacked to form a preform. The sheets may comprise a binding agent or a tackifier, e.g. dry fabric or prepreg. The sheets may be consolidated or precured by e.g. by heating, to attach the sheets to each other, and to form a preform of an inlay.
In
In
The inlays typically have a length D1 of 20-100 cm, a width D2 of 30-150 cm and a thickness D3 of 0.5-10 mm. The pultrusion layer typically has a length D11 of 40-80 m, a width D12 of 20-100 cm and a thickness D13 of 5-80 mm. The base part typically has a thickness D23 of 4-30 mm.
In
In
In
In
The inlay 50, 60 is made of sheets 90, 92, 94 arranged on top of each other. In
The inlay 50, 60 of
The thickness of each sheet may be between 0.2-0.8 mm, such as around 0.6 mm. The inlay 50, 60 comprising the sheets 90, 92, 94 has a thickness D3. The thickness D3 may be between 0.6-2.4 mm, such as around 1.8 mm.
For illustrative purposes the sheets are illustrated with straight ends. However, the ends may be chamfered, such as illustrated in
The method 200 comprises providing 202 a shell, such as a shell half, such as a pressure side shell half. The method 200 may optionally comprise arranging 204 a plurality of fibre layers on an inner surface of the shell to from a base part of a reinforced section.
The method 200 may comprise providing 207 a preform for a first inlay. Providing 207 the preform of the first inlay may comprise stacking 208 sheets of fibres, such as sheets of glass fibres, on top of each other. Each sheet may comprise a binding agent, such as glue. Providing 207 the preform of the first inlay may comprise consolidating 209 the sheets to form a preform with a harder and stiffer property.
The method 200 comprises arranging 210 a preform of a first inlay on the inner surface of the shell and/or on the base part of the reinforced section. Arranging 210 the preform of the first inlay may comprise arranging 212 the preform of the first inlay such that it is closer to the root end of the blade than the preform of the second inlay. Arranging 210 the preform of the first inlay may comprise arranging 214 the preform of the first inlay such that it extends underneath the entire proximal edge of a pultrusion layer. Arranging 210 the preform of the first inlay may comprise arranging 216 the preform of the first inlay such that a proximal edge of the preform of the first inlay is closer to the root than a proximal edge of a pultrusion layer.
The method 200 may comprise providing 217 a preform for a second inlay. Providing 217 the preform of the second inlay may comprise stacking 218 sheets of fibres, such as sheets of glass fibres, on top of each other. Each sheet may comprise a binding agent, such as glue. Providing 217 the preform of the second inlay may comprise consolidating 219 the sheets to form a preform with a harder and stiffer property.
The method 200 comprises arranging 220 a preform of a second inlay on the inner surface of the shell and/or on the base part of the reinforced section. Arranging 220 the preform of the second inlay may comprise arranging 222 the preform of the second inlay such that it is closer to the tip end of the blade than the preform of the first inlay. Arranging 220 the preform of the second inlay may comprise arranging 224 the preform of the second inlay such that it extends underneath the entire distal edge of a pultrusion layer. Arranging 220 the preform of the second inlay may comprise arranging 226 the preform of the second inlay such that a distal edge of the preform of the second inlay is closer to the tip than a distal edge of a pultrusion layer.
The method 200 comprises arranging 230 at least one pultrusion layer on the preform of the first inlay, the preform of the second inlay, the inner surface of the shell and/or on the base part of the reinforced section. The pultrusion layer comprises a plurality of pultruded members grouped together and the pultrusion layer is arranged in a spanwise direction of the blade. Arranging 230 the pultrusion layer comprises arranging 232 the pultrusion layer such that a proximal edge of the pultrusion layer is arranged on the preform of first inlay and a distal edge of the pultrusion layer is arranged on the preform of the second inlay. Arranging 230 the pultrusion layer may comprise arranging 234 the pultrusion layer such that that its proximal edge is closer to the root end of the blade than its distal end.
The method 200 may comprise arranging 240 a preform of a third inlay and/or arranging 250 a preform of a fourth inlay on top of the inner surface of the shell and/or at least a part of the base part of the reinforced section.
The method 200 may comprise infusing 260 the pultrusion layer, the preform of the first inlay, the preform of the second inlay, and optionally the base part of the reinforced section with a resin to form a reinforced section of the shell part of the wind turbine blade. Infusing 260 the pultrusion layer, the preform of the first inlay, the preform of the second inlay, and optionally the base part of the reinforced section with a resin may comprise applying 262 vacuum, such as during vacuum assisted resin transfer moulding (VARTM).
The method 200 may comprise manufacturing a second reinforced shell part. Manufacturing a second reinforced shell part comprises providing 1202 a second shell, such as a shell half, such as a suction side shell. The method may comprise arranging 1204 a plurality of fibre layers on an inner surface of the second shell to from a base part of a reinforced section.
The method 200 may comprise providing 1207 a preform for a first inlay. Providing 1207 the preform of the first inlay may comprise stacking 1208 sheets of fibres, such as sheets of glass fibres, on top of each other. Each sheet may comprise a binding agent, such as glue. Providing 1207 the preform of the first inlay may comprise consolidating 1209 the sheets to form a preform with a harder and stiffer property.
The method 200 may comprise arranging 1210 a preform of a first inlay on the inner surface of the second shell and/or on the base part of the reinforced section. Arranging 1210 the preform of the first inlay may comprise arranging 1212 the preform of the first inlay such that it is closer to the root end of the blade than the preform of the second inlay. Arranging 1210 the preform of the first inlay may comprise arranging 1214 the preform of the first inlay such that it extends underneath the entire proximal edge of the pultrusion layer. Arranging 1210 the preform of the first inlay may comprise arranging 1216 the preform of the first inlay such that a proximal edge of the preform of the first inlay is closer to the root than a proximal edge of the pultrusion layer.
The method 200 may comprise providing 1217 a preform for a second inlay. Providing 1217 the preform of the second inlay may comprise stacking 1218 sheets of fibres, such as sheets of glass fibres, on top of each other. Each sheet may comprise a binding agent, such as glue. Providing 1217 the preform of the second inlay may comprise consolidating 1219 the sheets to form a preform with a harder and stiffer property.
The method 200 may comprise arranging 1220 a preform of a second inlay on the inner surface of the second shell and/or on the base part of the reinforced section. Arranging 220 the preform of the second inlay may comprise arranging 1222 the preform of the second inlay such that it is closer to the tip end of the blade than the preform of the first inlay. Arranging 1220 the preform of the second inlay may comprise arranging 1224 the preform of the second inlay such that it extends underneath the entire distal edge of the pultrusion layer. Arranging 1220 the preform of the second inlay may comprise arranging 1226 the preform of the second inlay such that a distal edge of the preform of the second inlay is closer to the tip than a distal edge of the pultrusion layer.
The method 200 may comprise arranging 1230 at least one pultrusion layer on the preform of the first inlay, the preform of the second inlay, the inner surface of the shell of the base part of the reinforced section. The pultrusion layer comprises a plurality of pultruded members grouped together and the pultrusion layer is arranged in a spanwise direction of the blade. Arranging 1230 the pultrusion layer may comprise arranging 1232 the pultrusion layer such that a proximal edge of the pultrusion layer is arranged on the preform of first inlay and a distal edge of the pultrusion layer is arranged on the preform of the second inlay. Arranging 1230 the pultrusion layer may comprise arranging 1234 the pultrusion layer such that that its proximal edge is closer to the root end of the blade than its distal end.
The method 200 may comprise arranging 1240 a preform of a third inlay and/or arranging 1250 a preform of a fourth inlay on top of the inner surface of the second shell and/or the base part of the reinforced section.
The method 200 may comprise infusing 1260 the pultrusion layer, the preform of the first inlay, the preform of the second inlay, and optionally the base part of the reinforced section with a resin to form a reinforced section of the second shell part of the wind turbine blade. Infusing 1260 the pultrusion layer, the preform of the first inlay, the preform of the second inlay, and optionally the base part of the reinforced section with a resin may comprise applying 1262 vacuum, such as during vacuum assisted resin transfer moulding (VARTM).
The method 200 may comprise joining 2200 the two shell parts such that the inner surface of the two shells face each other to form a wind turbine blade.
The invention has been described with reference to preferred embodiments. However, the scope of the invention is not limited to the illustrated embodiments, and alterations and modifications can be carried out without deviating from the scope of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 19166212.1 | Mar 2019 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2020/058777 | 3/27/2020 | WO | 00 |
