Patent Application
20220266548
The present disclosure relates to wind turbine blades and manufacture of wind turbine blades. More specifically, the present disclosure pertains to the field of manufacturing of parts of a wind turbine blade, such as reinforcement parts of blade shells, such as blade shell parts, shear webs, spar beams, spar caps etc.
Wind turbine blades of fibre-reinforced polymer and in particular the aerodynamic shells of wind turbine blades are usually manufactured in moulds, where the pressure side and the suction side of the blade are manufactured separately by arranging glass fibre mats and/or other fibre-reinforcement material, such as carbon fibre, in each of the two moulds. Afterwards, one of the two halves is 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.
A wind turbine blade and/or components of the wind turbine blade, such as webs and/or shells, may be manufactured by infusing fibres, such as glass fibre mats and/or carbon fibre mats with a resin, such as polyester or epoxy. Infusion of the fibres may be provided by vacuum assisted resin transfer moulding (VARTM).
As wind turbines and wind turbine blades increase in size, the blade loads, i.e. strains, bending moments, peel loads etc., increase. For this and other reasons, precision in placement of component is of an increasing importance.
There is a desire to improve the process of manufacturing parts for a wind turbine blade and to reduce the total manufacturing time for a wind turbine blade. More specifically, it is a desire to reduce the in-mould manufacturing time for wind turbine blades to provide a faster turnaround time. By manufacturing as many parts offline and laying the pre-formed part in the mould, the in-mould manufacturing time can be reduced.
Furthermore, a more precise and easier way of manufacturing parts comprising pre-shaped elements, such as pultruded members, would also reduce the total manufacturing time and improve the quality of the wind turbine blades.
It is an object of the present disclosure to provide a part element for a wind turbine blade and a method for manufacturing a part for a wind turbine blade, 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 part element for a wind turbine blade and a method for manufacturing a part element for a wind turbine blade, which improves the process of positioning of components as well as facilitating decreased manufacturing time. Improvement in the process of positioning components may further decrease manufacturing variations and enhance mechanical properties of the assembled blade.
Thus, the present invention relates to a part element for a wind turbine blade. The part element comprises a primary sheet having a primary first side and a primary second side. The primary sheet may comprise fibres, e.g. the primary sheet may comprise fibres extending in a longitudinal direction and in a transverse direction. The part element, such as the primary sheet comprises one or more fibre threads, e.g. a first fibre thread extending in a primary first direction. The one or more fibre threads forms one or more loops on the primary first side of the primary sheet. The first fibre thread forms a first primary loop on the primary first side of the primary sheet from a primary first L1 point to a primary first L2 point. The first fibre thread, such as a first end of the first fibre thread, is anchored to the primary sheet.
The first fibre thread is anchored, such as to prevent movement of the first fibre end relative to the primary sheet, such as relative to other fibres of the primary sheet. The first fibre thread may be anchored by creating a first stitch, e.g. where the first stitch is a backstitch. A stitch may be obtained when the fibre thread is sewn through the sheet. A backstitch may be obtained by sewing the fibre thread through the sheet, e.g. from the primary second side, at a point of entry and returning though the sheet, e.g. to the primary second side, at a point of exit, wherein the point of exit is more proximal to the first end of the fibre thread than the point of entry. A backstitch may lock the fibre thread. Two backstitches may lock the fibre thread, e.g. such that loops between the two backstitches may maintain their sizes.
An alternative to a backstitch may be a running stitch. A running stitch may be obtained by sewing the fibre thread through the sheet, e.g. from the primary second side, at a point of entry and returning through the sheet, e.g. to the primary second side, at a point of exit, wherein the point of exit is more distal to the first end of the fibre thread than the point of entry. A running stitch may not limit a pull of the fibre thread, e.g. such that loops confined by running stitches may change in size.
Backstitches may have the advantage of providing fixed sizes of the loops. Running stitches may have the advantage of variable loop sizes. Any number of stitches of any type may be provided between the loops.
Also disclosed is a method for manufacturing a part element for a wind turbine blade. The method comprises providing a primary sheet having a primary first side and a primary second side. The primary sheet may comprise fibres, e.g. the primary sheet may comprise fibres extending in a longitudinal direction and in a transverse direction. The method may comprise providing one or more fibre threads, such as a first fibre thread. The primary sheet may comprise the first fibre thread. The first fibre thread may extend in a primary first direction. The first fibre thread forms a first primary loop on the primary first side of the primary sheet. from a primary first L1 point to a primary first L2 point. The first fibre thread, such as a first end of the first fibre thread, is anchored to the primary sheet.
It is an advantage of the present disclosure that an easier way of laying up layers may be provided, as the part element provides a more flexible and easier way of controlling the position between elements. Particularly, looped fibres may provide for restraining of elements, thereby providing a way of better controlling and/or restricting movement between elements.
It is a further advantage of the present disclosure that the part element may allow for high drapability and ability to adapt better to curved surfaces than current solutions.
It is an even further advantage of the present disclosure that layers may be laid up outside the blade shell mould, since the disclosed part element facilitates an improved method of transferring pre-shaped elements.
The first fibre thread may extend alternatingly on the primary first side and the primary second side in the primary first direction. The first fibre thread may extend at least partly on the primary second side of the primary sheet from the primary first L1 point to a primary first L0 point. The first fibre thread may extend at least partly on the primary second side of the primary sheet from the primary first L2 point to a primary first L3 point. The first fibre thread may form a first secondary loop on the primary first side of the primary sheet from the primary first L3 point to a primary first L4 point. Alternatively or additionally, the first fibre thread may form a first tertiary loop on the primary first side of the primary sheet from a primary first L5 point to a primary first L6 point.
The primary first direction may be parallel to the longitudinal direction of the primary sheet. Alternatively, the primary first direction may be perpendicular to the longitudinal direction of the primary sheet, e.g. the primary first direction may be parallel to the transverse direction of the primary sheet.
The part element, e.g. the primary sheet of the part element, may comprise a second fibre thread extending in a primary second direction and forming a second primary loop on the primary first side of the primary sheet from a primary second L1 point to a primary second L2 point. The first fibre thread and the second fibre thread may extend substantially parallel. The second fibre thread, such as a first end of the second fibre thread, may be anchored to the primary sheet.
The second fibre thread may extend alternatingly on the primary first side and the primary second side in the primary second direction. The second fibre thread may extend at least partly on the primary second side of the primary sheet from the primary second L1 point to a primary second L0 point. The second fibre thread may extend at least partly on the primary second side of the primary sheet from the primary second L2 point to a primary second L3 point. The second fibre thread may form a second secondary loop on the primary first side of the primary sheet from a primary second L3 point to a primary second L4 point. Alternatively or additionally, the second fibre thread may form a second tertiary loop on the primary first side of the primary sheet from a primary second L5 point to a primary second L6 point.
The first fibre thread and the second fibre thread may extend parallel on the primary first side. The first fibre thread and the second fibre thread may extend parallel on the primary second side. The primary second direction may be parallel to the longitudinal direction of the primary sheet. Alternatively, the primary second direction may be perpendicular to the longitudinal direction of the primary sheet, e.g. the primary second direction may be parallel to the transverse direction of the primary sheet. The primary second direction may be parallel or perpendicular to the primary first direction.
The part element, e.g. the primary sheet of the part element may comprise a third fibre thread extending in a primary third direction. The third fibre thread may form a third primary loop on the primary first side of the primary sheet from a primary third T1 point to a primary third T2 point. The first fibre thread and the third fibre thread may extend substantially perpendicular. The second fibre thread and the third fibre thread may extend substantially perpendicular. A first end of the third fibre thread may be anchored to the primary sheet.
The third fibre thread may extend alternatingly on the primary first side and the primary second side in the primary third direction. The third fibre thread may extend at least partly on the primary second side of the primary sheet from the primary third T1 point to a primary third T0 point. The third fibre thread may extend at least partly on the primary second side of the primary sheet from the primary third T2 point to a primary third T3 point. The third fibre thread may form a third secondary loop on the primary first side of the primary sheet from the primary third T3 point to a primary third T4 point. Alternatively or additionally, the third fibre thread may form a third tertiary loop on the primary first side of the primary sheet from a primary third T5 point to a primary third T6 point.
The primary third direction may be parallel to the transverse direction of the primary sheet. Alternatively, the primary third direction may be perpendicular to the transverse direction of the primary sheet, e.g. the primary third direction may be parallel to the longitudinal direction of the primary sheet. The primary third direction may be perpendicular to the primary first direction and/or the primary second direction. The primary third direction may be different than the primary first direction and/or the primary second direction. The third primary loop may be located between the first fibre thread and the second fibre thread.
The part element, e.g. the primary sheet of the part element, may comprise a fourth fibre thread extending in a primary fourth direction. The fourth fibre thread may form a fourth primary loop on the primary first side of the primary sheet from a primary fourth T1 point to a primary fourth T2 point.
The fourth fibre thread may extend alternatingly on the primary first side and the primary second side in the primary fourth direction. The fourth fibre thread may extend at least partly on the primary second side of the primary sheet from the primary fourth T1 point to a primary fourth T0 point. The fourth fibre thread may extend at least partly on the primary second side of the primary sheet from the primary fourth T2 point to a primary fourth T3 point. The fourth fibre thread may form a fourth secondary loop on the primary first side of the primary sheet from the primary fourth T3 point to a primary fourth T4 point. Alternatively or additionally, the fourth fibre thread may form a fourth tertiary loop on the primary first side of the primary sheet from a primary fourth T5 point to a primary fourth T6 point.
The primary fourth direction may be parallel to the transverse direction of the primary sheet. Alternatively, the primary fourth direction may be perpendicular to the transverse direction of the primary sheet, e.g. the primary fourth direction may be parallel to the longitudinal direction of the primary sheet. The primary fourth direction may be perpendicular to the primary first direction and/or the primary second direction. The primary fourth direction may be parallel to the primary third direction. The primary fourth direction may be different than the primary first direction and/or the primary second direction.
The part element, e.g. the primary sheet of the part element, may comprise a fifth fibre thread extending in a primary fifth direction. The fifth fibre thread may form a fifth primary loop on the primary first side of the primary sheet from a primary fifth L1 point to a primary fifth L2 point.
The fifth fibre thread may extend alternatingly on the primary first side and the primary second side in the primary fourth direction. The fifth fibre thread may extend at least partly on the primary second side of the primary sheet from the primary fifth L1 point to a primary fifth L0 point. The fifth fibre thread may extend at least partly on the primary second side of the primary sheet from the primary fifth L2 point to a primary fifth L3 point. The fifth fibre thread may form a fifth secondary loop on the primary first side of the primary sheet from the primary fifth L3 point to a primary fifth L4 point. Alternatively or additionally, the fifth fibre thread may form a fifth tertiary loop on the primary first side of the primary sheet from a primary fifth L5 point to a primary fifth L6 point.
The primary fifth direction may be parallel to the longitudinal direction of the primary sheet. Alternatively, the primary fifth direction may be perpendicular to the longitudinal direction of the primary sheet, e.g. the primary fifth direction may be parallel to the transverse direction of the primary sheet. The primary fifth direction may be parallel to the primary first direction and/or the primary second direction. The primary fifth direction may be perpendicular to the primary third direction and/or the primary fourth direction. The primary fifth direction may be different than the primary third direction and/or the primary fourth direction.
The second fibre thread and/or the third fibre thread and/or the fourth fibre thread and/or the fifth fibre thread may be anchored, such as to prevent movement of the first fibre end relative to the primary sheet, such as relative to other fibres of the primary sheet.
The first fibre thread and/or second fibre thread and/or third fibre thread and/or fourth fibre thread and/or fifth fibre thread may comprise materials such as glass fibre, carbon fibre, cotton, linen, flax, hemp, synthetic filaments or any other similar material.
The part element may comprise a secondary sheet. The method may comprise providing the secondary sheet. The secondary sheet may comprise fibres, e.g. the secondary sheet may comprise fibres extending in a longitudinal direction and/or in a transverse direction. The secondary sheet may have a secondary first side and a secondary second side.
The secondary sheet and the primary sheet may be arranged such that the primary first side of the primary sheet is facing the secondary second side of the secondary sheet. The first primary loop may be provided to extend to the secondary first side of the secondary sheet. The second primary loop may be provided to extend to the secondary first side of the secondary sheet.
The secondary sheet may comprise a first primary slit extending in a secondary first direction from a secondary first L1 point to a secondary first L2 point. The first primary slit may be configured to receive part of the first fibre thread, e.g. the first primary loop or at least a part of the first primary loop. The first primary loop may extend through the first primary slit.
The secondary sheet may comprise a first secondary slit extending in the secondary first direction from a secondary first L3 point to a secondary first L4 point. The first secondary slit may be configured to receive part of the first fibre thread, e.g. the first secondary loop or at least a part of the first secondary loop. The first secondary loop may extend through the first secondary slit. The secondary sheet may comprise a first tertiary slit extending in the secondary first direction from a secondary first L5 point to a secondary first L6 point. The first tertiary slit may be configured to receive part of the first fibre thread, e.g. the first tertiary loop or at least a part of the first tertiary loop. The first tertiary loop may extend through the first tertiary slit.
The secondary sheet may comprise a second primary slit. The second primary slit may extend in a secondary second direction. The second primary slit may extend from a secondary second L1 point to a secondary second L2 point. The second primary slit may be configured to receive part of the second fibre thread, e.g. the second primary loop or at least a part of the second primary loop. The second primary loop may extend through the second primary slit. The secondary sheet may comprise a second secondary slit extending in the secondary second direction from a secondary second L3 point to a secondary second L4 point. The second secondary slit may be configured to receive part of the second fibre thread, e.g. the second secondary loop or at least a part of the second secondary loop. The second secondary loop may extend through the second secondary slit. The secondary sheet may comprise a second tertiary slit extending in the secondary second direction from a secondary second L5 point to a secondary second L6 point. The second tertiary slit may be configured to receive part of the second fibre thread, e.g. the second tertiary loop or at least a part of the second tertiary loop. The second tertiary loop may extend through the second tertiary slit. The secondary first direction and the secondary second direction may be substantially parallel. The first primary slit, the first secondary slit, the first tertiary slit, the second primary slit, the second secondary slit, and/or the second tertiary slit may extend substantially parallel.
The secondary sheet may comprise a third primary slit. The third primary slit may extend in a secondary third direction. The third primary slit may extend from a secondary third T1 point to a secondary third T2 point. The third slit may be configured to receive part of the third fibre thread, e.g. the third primary loop or at least a part of the third primary loop. The third primary loop may extend through the third primary slit. The secondary sheet may comprise a third secondary slit extending in the secondary third direction from a secondary third T3 point to a secondary third T4 point. The third secondary slit may be configured to receive part of the third fibre thread, e.g. the third secondary loop or at least a part of the third secondary loop. The third secondary loop may extend through the third secondary slit. The secondary sheet may comprise a third tertiary slit extending in the secondary third direction from a secondary third T5 point to a secondary third T6 point. The third tertiary slit may be configured to receive part of the third fibre thread, e.g. the third tertiary loop or at least a part of the third tertiary loop. The third tertiary loop may extend through the third tertiary slit. The secondary first direction and the secondary third direction may be substantially perpendicular. The secondary second direction and the secondary third direction may be substantially perpendicular. The third primary slit may extend in a direction different than the secondary second direction and/or the secondary first direction.
The secondary sheet may comprise a fourth primary slit. The fourth primary slit may extend in a secondary fourth direction. The fourth primary slit may extend from a secondary fourth T1 point to a secondary fourth T2 point. The fourth suit may be configured to receive part of the fourth fibre thread, e.g. the fourth primary loop or at least a part of the fourth primary loop. The fourth primary loop may extend through the fourth primary slit. The secondary sheet may comprise a fourth secondary slit extending in the secondary fourth direction from a secondary fourth T3 point to a secondary fourth T4 point. The fourth secondary slit may be configured to receive part of the fourth fibre thread, e.g. the fourth secondary loop or at least a part of the fourth secondary loop. The fourth secondary loop may extend through the fourth secondary slit. The secondary sheet may comprise a fourth tertiary slit extending in the secondary fourth direction from a secondary fourth T5 point to a secondary fourth T6 point. The fourth tertiary slit may be configured to receive part of the fourth fibre thread, e.g. the fourth tertiary loop or at least a part of the fourth tertiary loop. The fourth tertiary loop may extend through the fourth tertiary slit. The secondary first direction and the secondary fourth direction may be substantially perpendicular. The secondary second direction and the secondary fourth direction may be substantially perpendicular. The secondary third direction and the secondary fourth direction may be substantially parallel. The fourth primary slit may extend in a direction different than the secondary second direction and/or the secondary first direction, e.g. the secondary fourth direction may be perpendicular to the secondary second direction and/or the secondary first direction. The fourth primary slit and the third primary slit may extend substantially parallel.
The secondary sheet may comprise a fifth primary silt. The fifth primary slit may extend in a secondary fifth direction. The fifth primary slit may extend from a secondary fifth L1 point to a secondary fifth L2 point. The fifth primary slit may be configured to receive part of the fifth fibre thread, e.g. the fifth primary loop or at least a part of the fifth primary loop. The fifth primary loop may extend through the fifth primary slit. The secondary sheet may comprise a fifth secondary slit extending in the secondary fifth direction from a secondary fifth L3 point to a secondary fifth L4 point. The fifth secondary sit may be configured to receive part of the fifth fibre thread, e.g. the fifth secondary loop or at least a part of the fifth secondary loop. The fifth secondary loop may extend through the fifth secondary silt. The secondary sheet may comprise a fifth tertiary slit extending in the secondary fifth direction from a secondary fifth L5 point to a secondary fifth L6 point. The fifth tertiary silt may be configured to receive part of the fifth fibre thread, e.g. the fifth tertiary loop or at least a part of the fifth tertiary loop. The fifth tertiary loop may extend through the fifth tertiary slit. The secondary first direction and the secondary fifth direction may be substantially parallel. The secondary second direction and the secondary fifth direction may be substantially parallel. The secondary third direction and the secondary fifth direction may be substantially perpendicular. The secondary fourth direction and the secondary fifth direction may be substantially perpendicular. The fifth primary slit and the first primary slit may extend substantially parallel.
The secondary sheet may have a secondary first side and a secondary second side. The primary first side of the primary sheet may be arranged to face the secondary sheet, e.g. such as to face the secondary second side of the secondary sheet.
The primary sheet and the secondary sheet may be arranged such that the primary first L1 point of the primary sheet is aligned with the secondary first L1 point of the secondary sheet and/or such that the primary first L2 point of the primary sheet is aligned with the secondary first L2 point of the secondary sheet. The primary sheet and the secondary sheet may be arranged such that the primary first L3 point of the primary sheet is aligned with the secondary first L3 point of the secondary sheet and/or such that the primary first L4 point of the primary sheet is aligned with the secondary first L4 point of the secondary sheet. The primary sheet and the secondary sheet may be arranged such that the primary first L5 point of the primary sheet is aligned with the secondary first L5 point of the secondary sheet and/or such that the primary first L6 point of the primary sheet is aligned with the secondary first L6 point of the secondary sheet.
The primary sheet and the secondary sheet may be arranged such that the primary second L1 point of the primary sheet is aligned with the secondary second L1 point of the secondary sheet and/or such that the primary second L2 point of the primary sheet is aligned with the secondary second L2 point of the secondary sheet. The primary sheet and the secondary sheet may be arranged such that the primary second L3 point of the primary sheet is aligned with the secondary second L3 point of the secondary sheet and/or such that the primary second L4 point of the primary sheet is aligned with the secondary second L4 point of the secondary sheet. The primary sheet and the secondary sheet may be arranged such that the primary second L5 point of the primary sheet is aligned with the secondary second L5 point of the secondary sheet and/or such that the primary second L6 point of the primary sheet is aligned with the secondary second L6 point of the secondary sheet.
The primary sheet and the secondary sheet may be arranged such that the primary third L1 point of the primary sheet is aligned with the secondary third L1 point of the secondary sheet and/or such that the primary third L2 point of the primary sheet is aligned with the secondary third L2 point of the secondary sheet. The primary sheet and the secondary sheet may be arranged such that the primary third L3 point of the primary sheet is aligned with the secondary third L3 point of the secondary sheet and/or such that the primary third L4 point of the primary sheet is aligned with the secondary third L4 point of the secondary sheet. The primary sheet and the secondary sheet may be arranged such that the primary third L5 point of the primary sheet is aligned with the secondary third L5 point of the secondary sheet and/or such that the primary third L6 point of the primary sheet is aligned with the secondary third L6 point of the secondary sheet.
The primary sheet and the secondary sheet may be arranged such that the primary fourth L1 point of the primary sheet is aligned with the secondary fourth L1 point of the secondary sheet and/or such that the primary fourth L2 point of the primary sheet is aligned with the secondary fourth L2 point of the secondary sheet. The primary sheet and the secondary sheet may be arranged such that the primary fourth L3 point of the primary sheet is aligned with the secondary fourth L3 point of the secondary sheet and/or such that the primary fourth L4 point of the primary sheet is aligned with the secondary fourth L4 point of the secondary sheet. The primary sheet and the secondary sheet may be arranged such that the primary fourth L5 point of the primary sheet is aligned with the secondary fourth L5 point of the secondary sheet and/or such that the primary fourth L6 point of the primary sheet is aligned with the secondary fourth L6 point of the secondary sheet.
The primary sheet and the secondary sheet may be arranged such that the primary fifth L1 point of the primary sheet is aligned with the secondary fifth L1 point of the secondary sheet and/or such that the primary fifth L2 point of the primary sheet is aligned with the secondary fifth L2 point of the secondary sheet. The primary sheet and the secondary sheet may be arranged such that the primary fifth L3 point of the primary sheet is aligned with the secondary fifth L3 point of the secondary sheet and/or such that the primary fifth L4 point of the primary sheet is aligned with the secondary fifth L4 point of the secondary sheet. The primary sheet and the secondary sheet may be arranged such that the primary fifth L5 point of the primary sheet is aligned with the secondary fifth L5 point of the secondary sheet and/or such that the primary fifth L6 point of the primary sheet is aligned with the secondary fifth L6 point of the secondary sheet.
The primary sheet and/or the secondary sheet may be a piece of light fabric or cloth of glass fibre, carbon fibre, cotton, linen, flax, hemp, synthetic filaments or any other similar material.
The part element may comprise one or more pre-shaped elements, e.g. Including a first pre-shaped element and/or a second pre-shaped element. The method may comprise providing a pre-shaped element, such as the first pre-shaped element and/or the second pre-shaped element. The pre-shaped element(s) may be pultruded element(s), such as pultruded strips, e.g. the first pre-shaped element may be a first pultruded element and/or a first pultruded strip and/or the second pre-shaped element may be a second pultruded element and/or a second pultruded strip. The pre-shaped element(s), such as the first pre-shaped element and/or the second pre-shaped element may be arranged, e.g. positioned, between the first fibre thread and the second fibre thread. The pre-shaped element(s) may comprise carbon material. For example, the pre-shaped element(s) may be pultruded carbon element(s).
The pre-shaped element(s) may be positioned on the primary sheet. The pre-shaped element(s) may be positioned between the primary sheet and the secondary sheet. The pre-shaped element(s) may be positioned between the first fibre thread and the second fibre thread. The pre-shaped element(s) may be positioned between the first primary loop and the second primary loop. Alternatively, or additionally, the pre-shaped element(s) may be positioned between the third fibre thread and the fourth fibre thread, e.g. between the third primary loop and the fourth primary loop. The pre-shaped element(s) may be positioned after providing the first fibre thread and/or the second fibre thread. The pre-shaped element(s) may be positioned after arranging the secondary sheet and the primary sheet and/or after providing the first primary loop to extend to the secondary first side of the secondary sheet and/or after providing the second primary loop to extend to the secondary first side of the secondary sheet. By providing the pre-shaped elements after providing the fibre threads, the pre-shaped element(s) may be positioned more precisely as provision of the fibre threads does not risk disturbing the positioning of the pre-shaped elements.
The second pre-shaped element may be aligned with the first pre-shaped element, e.g. the first pre-shaped element and the second pre-shaped element may extend in the longitudinal direction between the same points and/or the first pre-shaped element and the second pre-shaped element may extend in the transverse direction between the same points. For example, the second pre-shaped element may be arranged between the first fibre thread and the second fibre thread, e.g. between the first primary loop and the second primary loop. Alternatively, or additionally, the second pre-shaped element may be positioned between the third fibre thread and the fourth fibre thread, e.g. between the third primary loop and the fourth primary loop. The first pre-shaped element and the second pre-shaped element may be stacked, e.g. the second pre-shaped element may be arranged on top of the first pre-shaped element.
The first pre-shaped element and the second pre-shaped element may be arranged following each other in the longitudinal direction, e.g. the first pre-shaped element and the second pre-shaped element may be arranged after each other along the longitudinal direction. Alternatively, the first pre-shaped element and the second pre-shaped element may be arranged after each other along the transverse direction, e.g. the first pre-shaped element and the second pre-shaped element may be arranged next to each other in the transverse direction. The pre-shaped elements, such as the first pre-shaped element and the second pre-shaped elements may have different lengths, widths and/or thicknesses.
The secondary sheet may be arranged such that the first primary slit is aligned with the first primary loop and the second primary slit is aligned with the second primary loop, and such that the pre-shaped element is arranged between the primary sheet and the secondary sheet. The first primary loop may be pulled through the first primary slit in the secondary sheet. The second primary loop may be pulled through the second primary slit in the secondary sheet.
The advantage of the present disclosure is an easier way of laying up layers comprising pultruded members, as the part element may provide a more flexible and easier way of controlling the position of the pre-shaped elements. The part element is moreover able to retain pultruded members of different sizes, which may give the part element a property of high drapability and ability to adapt better to curved surfaces than current solutions.
Furthermore, the layers may be laid up outside the blade shell mould, reducing in-mould manufacturing time, thus reducing the total manufacturing time. The part element may provide a better way of transferring pre-shaped elements onto other layers of materials, such as glass fibres, reducing the occurrence of wrinkles which may cause weak spots in a wind turbine blade.
The part element may comprise a first fibre strip. The method may comprise providing the first fibre strip. The first fibre strip may be configured to extend through the first primary loop and/or the second primary loop. Alternatively or additionally, the first fibre strip may be configured to extend through the third primary loop, the fourth primary loop, the first secondary loop and/or the fifth primary loop. The first fibre strip be a wide fibre strip, such as a tape. Alternatively, the fibre strip may have a thread or rope like shape, such as a yarn, such as a cotton yarn, such as a string or a tow. The fibre strip may comprise materials such as glass fibre, carbon fibre, cotton, linen, flax, hemp, synthetic filaments or any other similar material.
The first fibre strip may be pulled through the first primary loop of the first fibre thread and the second primary loop of the second fibre thread. The strip may be fastened or tightened to retain the pre-shaped element(s).
The first fibre strip may engage with a plurality of loops. The first fibre strip may engage with loops, such that the first fibre strip extends in a direction perpendicular to the longitudinal direction of the pre-shaped elements. The first fibre strip may engage with loops, such that the first fibre strip extends in direction at an angle between 0-180° relative to the longitudinal direction of the pre-shaped element(s). The first fibre strip may engage with loops in a first column, e.g. the first primary loop, the second primary loop, the third primary loop, the fourth primary loop and/or the fifth primary loop, and turn to engage with loops in a second column, e.g. the first secondary loop, the second secondary loop, the third secondary loop, the fourth secondary loop and/or the fifth secondary loop.
The part element may comprise the secondary sheet without the fibre strip for retaining the pre-shaped elements. The part element may comprise the fibre strip without the secondary sheet for retaining the pre-shaped elements. The part element may comprise both the secondary sheet and the fibre strip for retaining the pre-shaped elements.
The part element may comprise a tertiary sheet. The method may comprise providing the tertiary sheet. The tertiary sheet may comprise fibres, e.g. the tertiary sheet may comprise fibres extending in a longitudinal direction and/or in a transverse direction. The tertiary sheet may have a tertiary first side and a tertiary second side.
The tertiary sheet and the secondary sheet may be arranged such that the secondary first side of the secondary sheet is facing the tertiary second side of the tertiary sheet. The first primary loop may be provided to extend to the tertiary first side of the tertiary sheet. The second primary loop may be provided to extend to the tertiary first side of the tertiary sheet.
The tertiary sheet may comprise one or more slits configured to receive fibre threads, e.g. a part of loops.
The tertiary sheet may comprise a first primary slit extending in a tertiary first direction from a tertiary first L1 point to a tertiary first L2 point. The first primary slit may be configured to receive part of the first fibre thread, e.g. the first primary loop or at least a part of the first primary loop. The first primary loop may extend through the first primary slit.
The tertiary sheet may comprise a first secondary slit extending in the tertiary first direction from a tertiary first L3 point to a tertiary first L4 point. The first secondary slit may be configured to receive part of the first fibre thread, e.g. the first secondary loop or at least a part of the first secondary loop. The first secondary loop may extend through the first secondary slit. The tertiary sheet may comprise a first tertiary slit extending in the tertiary first direction from a tertiary first L5 point to a tertiary first L5 point. The first tertiary slit may be configured to receive part of the first fibre thread, e.g. the first tertiary loop or at least a part of the first tertiary loop. The first tertiary loop may extend through the first tertiary slit.
The tertiary sheet may comprise a second primary slit. The second primary slit may extend in a tertiary second direction. The second primary slit may extend from a tertiary second L1 point to a tertiary second L2 point. The second primary slit may be configured to receive part of the second fibre thread, e.g. the second primary loop or at least a part of the second primary loop. The second primary loop may extend through the second primary slit. The tertiary sheet may comprise a second secondary slit extending in the tertiary second direction from a tertiary second L3 point to a tertiary second L4 point. The second secondary slit may be configured to receive part of the second fibre thread, e.g. the second secondary loop or at least a part of the second secondary loop. The second secondary loop may extend through the second secondary slit. The tertiary sheet may comprise a second tertiary slit extending in the tertiary second direction from a tertiary second L5 point to a tertiary second L6 point. The second tertiary slit may be configured to receive part of the second fibre thread, e.g. the second tertiary loop or at least a part of the second tertiary loop. The second tertiary loop may extend through the second tertiary slit. The tertiary first direction and the tertiary second direction may be substantially parallel. The first primary slit, the first secondary slit, the first tertiary slit, the second primary slit, the second secondary slit, and/or the second tertiary slit may extend substantially parallel.
The tertiary sheet may comprise a third primary slit. The third primary slit may extend in a tertiary third direction. The third primary slit may extend from a tertiary third T1 point to a tertiary third T2 point. The third slit may be configured to receive part of the third fibre thread, e.g. the second primary loop or at least a part of the third primary loop. The third primary loop may extend through the third primary slit. The tertiary sheet may comprise a third secondary slit extending in the tertiary third direction from a tertiary third T3 point to a tertiary third T4 point. The third secondary slit may be configured to receive part of the third fibre thread, e.g. the third secondary loop or at least a part of the third secondary loop. The third secondary loop may extend through the third secondary slit. The tertiary sheet may comprise a third tertiary slit extending in the tertiary third direction from a tertiary third T5 point to a tertiary third T6 point. The third tertiary slit may be configured to receive part of the third fibre thread, e.g. the third tertiary loop or at least a part of the third tertiary loop. The third tertiary loop may extend through the third tertiary slit. The tertiary first direction and the tertiary third direction may be substantially perpendicular. The tertiary second direction and the tertiary third direction may be substantially perpendicular. The third primary slit may extend in a direction different than the tertiary second direction and/or the tertiary first direction.
The tertiary sheet may comprise a fourth primary slit. The fourth primary slit may extend in a tertiary fourth direction. The fourth primary slit may extend from a tertiary fourth T1 point to a tertiary fourth T2 point. The fourth slit may be configured to receive part of the fourth fibre thread, e.g. the fourth primary loop or at least a part of the fourth primary loop. The fourth primary loop may extend through the fourth primary slit. The tertiary sheet may comprise a fourth secondary slit extending in the tertiary fourth direction from a tertiary fourth T3 point to a tertiary fourth T4 point. The fourth secondary slit may be configured to receive part of the fourth fibre thread, e.g. the fourth secondary loop or at least a part of the fourth secondary loop. The fourth secondary loop may extend through the fourth secondary slit. The tertiary sheet may comprise a fourth tertiary slit extending in the tertiary fourth direction from a tertiary fourth T5 point to a tertiary fourth T6 point. The fourth tertiary slit may be configured to receive part of the fourth fibre thread, e.g. the fourth tertiary loop or at least a part of the fourth tertiary loop. The fourth tertiary loop may extend through the fourth tertiary slit. The tertiary first direction and the tertiary fourth direction may be substantially perpendicular. The tertiary second direction and the tertiary fourth direction may be substantially perpendicular. The tertiary third direction and the tertiary fourth direction may be substantially parallel. The fourth primary slit may extend in a direction different than the tertiary second direction and/or the tertiary first direction, e.g. the tertiary fourth direction may be perpendicular to the tertiary second direction and/or the tertiary first direction. The fourth primary slit and the third primary slit may extend substantially parallel.
The tertiary sheet may comprise a fifth primary slit. The fifth primary slit may extend in a tertiary fifth direction. The fifth primary slit may extend from a tertiary fifth L1 point to a tertiary fifth L2 point. The fifth primary slit may be configured to receive part of the fifth fibre thread, e.g. the fifth primary loop or at least a part of the fifth primary loop. The fifth primary loop may extend through the fifth primary slit. The tertiary sheet may comprise a fifth secondary slit extending in the tertiary fifth direction from a tertiary fifth L3 point to a tertiary fifth L4 point. The fifth secondary slit may be configured to receive part of the fifth fibre thread, e.g. the fifth secondary loop or at least a part of the fifth secondary loop. The fifth secondary loop may extend through the fifth secondary sit. The tertiary sheet may comprise a fifth tertiary slit extending in the tertiary fifth direction from a tertiary fifth L5 point to a tertiary fifth L6 point. The fifth tertiary slit may be configured to receive part of the fifth fibre thread, e.g. the fifth tertiary loop or at least a part of the fifth tertiary loop. The fifth tertiary loop may extend through the fifth tertiary slit. The tertiary first direction and the tertiary fifth direction may be substantially parallel. The tertiary second direction and the tertiary fifth direction may be substantially parallel. The tertiary third direction and the tertiary fifth direction may be substantially perpendicular. The tertiary fourth direction and the tertiary fifth direction may be substantially perpendicular. The fifth primary slit and the first primary slit may extend substantially parallel.
The tertiary sheet may have a tertiary first side and a tertiary second side. The secondary first side of the secondary sheet may be arranged to face the tertiary sheet, e.g. such as to face the tertiary second side of the tertiary sheet.
The primary sheet and the tertiary sheet may be arranged such that the primary first L1 point of the primary sheet is aligned with the tertiary first L1 point of the tertiary sheet and/or such that the primary first L2 point of the primary sheet is aligned with the tertiary first L2 point of the tertiary sheet. The tertiary sheet may be arranged such that the slits in the secondary sheet are aligned with the slits in the tertiary sheet.
The primary sheet and the tertiary sheet may be arranged such that the primary first L1 point of the primary sheet is aligned with the tertiary first L1 point of the tertiary sheet and/or such that the primary first L2 point of the primary sheet is aligned with the tertiary first L2 point of the tertiary sheet. The primary sheet and the tertiary sheet may be arranged such that the primary first L3 point of the primary sheet is aligned with the tertiary first L3 point of the tertiary sheet and/or such that the primary first L4 point of the primary sheet is aligned with the tertiary first L4 point of the tertiary sheet. The primary sheet and the tertiary sheet may be arranged such that the primary first L5 point of the primary sheet is aligned with the tertiary first L5 point of the tertiary sheet and/or such that the primary first L6 point of the primary sheet is aligned with the tertiary first L6 point of the tertiary sheet.
The primary sheet and the tertiary sheet may be arranged such that the primary second L1 point of the primary sheet is aligned with the tertiary second L1 point of the tertiary sheet and/or such that the primary second L2 point of the primary sheet is aligned with the tertiary second L2 point of the tertiary sheet. The primary sheet and the tertiary sheet may be arranged such that the primary second L3 point of the primary sheet is aligned with the tertiary second L3 point of the tertiary sheet and/or such that the primary second L4 point of the primary sheet is aligned with the tertiary second L4 point of the tertiary sheet. The primary sheet and the tertiary sheet may be arranged such that the primary second L5 point of the primary sheet is aligned with the tertiary second L5 point of the tertiary sheet and/or such that the primary second L6 point of the primary sheet is aligned with the tertiary second L6 point of the tertiary sheet.
The primary sheet and the tertiary sheet may be arranged such that the primary third L1 point of the primary sheet is aligned with the tertiary third L1 point of the tertiary sheet and/or such that the primary third L2 point of the primary sheet is aligned with the tertiary third L2 point of the tertiary sheet. The primary sheet and the tertiary sheet may be arranged such that the primary third L3 point of the primary sheet is aligned with the tertiary third L3 point of the tertiary sheet and/or such that the primary third L4 point of the primary sheet is aligned with the tertiary third L4 point of the tertiary sheet. The primary sheet and the tertiary sheet may be arranged such that the primary third L5 point of the primary sheet is aligned with the tertiary third L5 point of the tertiary sheet and/or such that the primary third L6 point of the primary sheet is aligned with the tertiary third L6 point of the tertiary sheet.
The primary sheet and the tertiary sheet may be arranged such that the primary fourth L1 point of the primary sheet is aligned with the tertiary fourth L1 point of the tertiary sheet and/or such that the primary fourth L2 point of the primary sheet is aligned with the tertiary fourth L2 point of the tertiary sheet. The primary sheet and the tertiary sheet may be arranged such that the primary fourth L3 point of the primary sheet is aligned with the tertiary fourth L3 point of the tertiary sheet and/or such that the primary fourth L4 point of the primary sheet is aligned with the tertiary fourth L4 point of the tertiary sheet. The primary sheet and the tertiary sheet may be arranged such that the primary fourth L5 point of the primary sheet is aligned with the tertiary fourth L5 point of the tertiary sheet and/or such that the primary fourth L6 point of the primary sheet is aligned with the tertiary fourth L6 point of the tertiary sheet.
The primary sheet and the tertiary sheet may be arranged such that the primary fifth L1 point of the primary sheet is aligned with the tertiary fifth L1 point of the tertiary sheet and/or such that the primary fifth L2 point of the primary sheet is aligned with the tertiary fifth L2 point of the tertiary sheet. The primary sheet and the tertiary sheet may be arranged such that the primary fifth L3 point of the primary sheet is aligned with the tertiary fifth L3 point of the tertiary sheet and/or such that the primary fifth L4 point of the primary sheet is aligned with the tertiary fifth L4 point of the tertiary sheet. The primary sheet and the tertiary sheet may be arranged such that the primary fifth L5 point of the primary sheet is aligned with the tertiary fifth L5 point of the tertiary sheet and/or such that the primary fifth L6 point of the primary sheet is aligned with the tertiary fifth L6 point of the tertiary sheet.
The tertiary sheet may be a piece of light fabric or cloth of glass fibre, carbon fibre, cotton, linen, flax, hemp, synthetic filaments or any other similar material.
One or more pre-shaped element(s), such as the first pre-shaped element, the second pre-shaped element and/or a third pre-shaped element may be arranged between the secondary sheet and the tertiary sheet.
The part element and/or sub-part of the part element may be transferred from a first position to a second position. The sub-part of the part element may refer to the primary sheet, the first pre-shaped element, the secondary sheet, the tertiary sheet, and/or other elements of the part element previously defined. The first position may be a pre-form mould. The second position may be a mould for manufacturing a spar beam or a mould for manufacturing a blade shell part. Transferring the part element and/or the sub-part may comprise attaching a transportation structure to the first fibre thread and/or the second fibre thread, e.g. attaching the transportation structure to the first primary loop and/or the second primary loop, e.g. by attaching the first primary loop and/or the second primary loop to hooks of the transportation structure.
Transferring the part element and/or the sub-part may comprise arranging the part element and/or the sub-part in a mould comprising an inclined surface. Arranging the part element and/or the sub-part may comprise aligning the part element on the inclined surface of the mould. Alternatively, the part element and/or the sub part may be arranged on a blade shell part in a blade shell mould.
The part element and/or the sub part may be Impregnated or infused with a resin. The method may comprise curing the part element and/or sub part, e.g. curing the resin thereof. The part element may be cured by infusing the part element with a resin. Infusion may be provided by vacuum assisted resin transfer moulding (VARTM). The part element and/or the sub part may be cured to provide a pre-form element before transferring the part element or sub part, e.g. the part element and/or sub part may be cured in the first position. Alternatively, the part element and/or sub part may be cured after transferring to a mould or a blade shell part, e.g. the part element and/or sub part may be cured in the second position. The part element and/or sub part may be cured in an inclined position, e.g. having an inclination between 0-90. The part element and/or sub part may be cured in a substantially horizontal position.
The primary sheet and/or the secondary sheet and/or the tertiary sheet may improve the infusion process by providing distribution paths for the resin. Thereby facilitating a more even distribution of the resin.
Also disclosed is a wind turbine blade comprising a part element, such as the above described part element, connecting a first blade section and a second blade section.
The first blade section may extend along a longitudinal axis from a root to a first end. The second blade section may extend along the longitudinal axis from a second end to a tip. The first blade section may comprise a root region and a first airfoil region. The second blade section may comprise a second airfoil region with the tip.
The part element may form a spar beam connecting the first blade section and the second blade section. The spar beam may longitudinally extend along a spar beam axis from a first beam position to a second beam position and may be positioned such that the first beam position is located in the first airfoil region and the second beam position is located in the second airfoil region. A third beam position, between the first beam position and the second beam position, may be aligned with the second end of the second blade section.
Alternatively, the part element may be used to hold dry fabric in place. The dry fabric may be arranged on the primary sheet and the dry fabric may comprise slits at corresponding locations to the loops of the primary sheet. The dry fabric may be arranged between a primary sheet and a secondary sheet. A fibre strip may be engaged with the loops of the primary sheet.
The part element may form a part of a wind turbine blade, such as a spar cap, a spar beam, a blade shell part, a shear web, a spar box. The part element may form part of a part of a wind turbine blade, such as a part of a spar cap, a spar beam, a blade shell part, a shear web, a spar box.
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. Uke reference numerals refer to like elements throughout. Uke 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 needs 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 or half shells, a first blade shell part 24 and a second blade shell part 26, typically made of fibre-reinforced polymer. The wind turbine blade 10 may comprise additional shell parts, such as a third shell part and/or a fourth shell part. 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 is a so-called split blade, or two-part blade, or segmented blade. The wind turbine blade 10 comprises a first blade section 44 and a second blade section 46. The first blade section 44 extends along the longitudinal axis L from a root, such as the root end 17, to a first end 50. The second blade section 46 extends along the longitudinal axis L from a second end 52 to a tip, such as the tip end 15. The first blade section 44 comprises a root region 30, a first airfoil region 34a and a transition region 32 between the root region 30 and the first airfoil region 34a. The second blade section 46 comprises a second airfoil region 34b with the tip, such as the tip end 15. The first blade section 44 and the second blade section 46 may be connected with a spar beam 48.
The part element 78 in
For illustrative purposes, the part element 78 illustrated in the following figures are configured according to the solution in
A third fibre thread 86′″ extends in a primary third direction 88′″ and the first end 92′″ of the third fibre thread 86′″ is anchored to the primary sheet 80, e.g. with a backstitch (see
The part element 78 comprises a secondary sheet 100. The secondary sheet 100 comprises a first primary slit 102′ extending between a secondary first L1 point SFL1 and a secondary first L2 point SFL2, a first secondary slit 132′ between a secondary first L3 point SFL3 and a secondary first L4 point SFL4, a second primary slit 102″ between a secondary second L1 point SSL1 and a secondary second L2 point SSL2, a third primary slit 102′″ between a secondary third T1 point STT1 and a secondary third T2 point STT2, and a fourth primary slit 102″″ between a secondary fourth T1 point SFT1 and a secondary fourth T2 point SFT2. The first primary loop 90′ engages with the first primary slit 102′ by extending through the first primary slit 102′, the first secondary loop 130′ engages with the first secondary slit 132′ by extending through the first secondary slit 132′, the second primary loop 90″ engages with the second primary slit 102″ by extending through the second primary slit 102″, the third primary loop 90′″ engages with the third primary slit 102′″ by extending through the third primary slit 102′″, the fourth primary loop 90″″ engages with the fourth primary slit 102″″ by extending through the fourth primary slit 102″″.
A first pre-shaped element 122′ is arranged between the primary sheet 80 and the secondary sheet 100. The first pre-shaped element 122′ is arranged between the first primary loop 90′, the first secondary loop 130′, the second primary loop 90″, the third primary loop 90′″ and the fourth primary loop 90″″. The first pre-shaped element 122′ extends in a direction substantially parallel to the primary first direction 88′ and/or the primary second direction 88″. The first pre-shaped element 122′ extends in a transverse direction between the first fibre thread 86′ and the second fibre thread 86″. The first pre-shaped element 122′ extends in a longitudinal direction between the third fibre thread 86′″ and the fourth fibre thread 86″″.
A second pre-shaped element 122″ is aligned with the first pre-shaped element 122′. The second pre-shaped element 122″ is arranged between the primary sheet 80 and the secondary sheet 100. The second pre-shaped element 122″ is arranged between the first primary loop 90′, the first secondary loop 130′, the second primary loop 90″, the third primary loop 90′″ and the fourth primary loop 90″″. The second pre-shaped element 122″ extends in a direction substantially parallel to the primary first direction 88′ and/or the primary second direction 88″. The second pre-shaped element 122″ extends in a transverse direction between the first fibre thread 86′ and the second fibre thread 86″. The second pre-shaped element 122″ extends in a longitudinal direction between the third fibre thread 86′″ and the fourth fibre thread 86″″.
The part element 78 illustrated in
The part element 78 comprises a secondary sheet 100. The secondary sheet 100 comprises a first primary slit 102′, a first secondary slit 132′, a second primary slit 102″, a second secondary slit 132″, a fifth primary slit 102′″″ and a fifth secondary slit 132′″″. The loops engage with the corresponding slits by extending through the slits.
A first pre-shaped element 122′ is arranged between the primary sheet 80 and the secondary sheet 100. The first pre-shaped element 122′ is arranged between the first fibre thread 86′ and the second fibre thread 86″. The first pre-shaped element 122′ extends in a direction substantially parallel to the primary first direction 88′ and/or the primary second direction 88″. The first pre-shaped element 122′ extends in a transverse direction between the first fibre thread 86′ and the second fibre thread 86″.
A third pre-shaped element 122′″ is aligned with the first pre-shaped element 122′. The third pre-shaped element 122′″ is arranged between the primary sheet 80 and the secondary sheet 100. The third pre-shaped element 122′″ is arranged between the second fibre thread 86″ and the fifth fibre thread 86′″″. The third pre-shaped element 122′″ extends in a direction substantially parallel to the primary first direction 88′ and/or the primary second direction 88″ and/or the primary fifth direction 88′″″. The third pre-shaped element 122′″ extends in a transverse direction between the second fibre thread 86″ and the fifth fibre thread 86′″″.
The part element 78 illustrated in
The primary sheet 80 comprises a fibre thread 86 forming loops 91. The secondary sheet 100 comprises slits 103. The loops 91 are engaging with the slits 103. Pre-shaped elements 122 are arranged between the primary sheet 80 and the secondary sheet 100. The part element 78 may be transferred, e.g. after assembly of the part element 78, by connecting the loops 91 to a transportation structure. The loops 91, which may be evenly distributed along the longitudinal direction of the pre-shaped elements support the pre-shaped elements 122 so that bending of the pre-shaped element 122 (e.g. as explained with respect to
The part element 78 may be transferred from a first position, such as a pre-form mould 152, as illustrated in
Alternatively, as schematically illustrated in
The method 200 comprises providing 202 a primary sheet, such as the primary sheet 80 of previous figures, having a primary first side and a primary second side. The primary sheet comprising fibres, e.g. the primary sheet may comprise fibres extending in a longitudinal direction and in a transverse direction. The primary sheet comprising a first fibre thread extending in a primary first direction and forming a first primary loop on the primary first side of the primary sheet from a primary first L1 point to a primary first L2 point, and wherein a first end of the first fibre thread is anchored to the primary sheet.
The primary sheet may comprise a second fibre thread extending in a primary second direction and forming a second primary loop on the primary first side of the primary sheet from a primary second L1 point to a primary second L2 point. The first fibre thread and the second fibre thread may extend substantially parallel, and wherein the second fibre thread is anchored to the primary sheet.
The method 200 optionally comprises providing 204 a pre-shaped element. The method optionally comprises positioning 206 the pre-shaped element on the primary sheet, e.g. between the first fibre thread and the second fibre thread, e.g. between the first primary loop and the second primary loop. A second pre-shaped element may be provided and arranged on top of the first pre-shaped element, alongside the first pre-shaped element in the longitudinal direction, or alongside the first pre-shaped element in the transverse direction. The pre-shaped elements may have different lengths, widths and thicknesses.
The method 200 comprises providing 208 a secondary sheet, such as the secondary sheet 100 as described with respect to previous figures. The secondary sheet comprises a first primary slit and optionally a second primary slit. The method 200 comprises arranging 210 the secondary sheet such that the first primary slit is aligned with the first primary loop and optionally such that the second primary slit is aligned with the second primary loop, and optionally such that the pre-shaped element is arranged between the primary sheet and the secondary sheet. The method 200 optionally comprises pulling 212 the first primary loop through the first primary slit in the secondary sheet and optionally pulling 214 the second primary loop through the second primary sit in the secondary sheet.
The method 200 optionally comprises providing 216 a first fibre strip and pulling 218 the first fibre strip through the first primary loop of the first fibre thread and/or the second primary loop of the second fibre thread. The strip may be fastened or tightened to retain the pre-shaped elements.
The part element may comprise the secondary sheet without the fibre strip for retaining the pre-shaped elements. The part element may comprise the fibre strip without the secondary sheet for retaining the pre-shaped elements. The part element may comprise both the secondary sheet and the fibre strip for retaining the pre-shaped elements.
The method 200 comprises transferring 220 the part element from a first position to a second position. The first position may be a pre-form mould. The second position may be a mould for manufacturing for example a spar beam or a mould for manufacturing a blade shell part.
Transferring 220 the part element may comprise attaching 222 a transportation structure to the first fibre thread and/or the second fibre thread, e.g. attaching the first primary loop and/or the second primary loop to hooks in the transportation structure.
Transferring 220 the part element may comprise arranging 224 the part element in a mould comprising an inclined surface, and wherein arranging the part element comprises aligning the part element on the inclined surface of the mould. Alternatively, the part element may be arranged 224 on a blade shell part in a blade shell mould.
The method 200 optionally comprises curing 226 the part element and/or a wind turbine blade part comprising the part element. The part element may be cured in the first position, e.g. In the pre-form mould, or in the second position, e.g. In the mould or the blade shell mould. The part element may be cured by infusing the part element with a resin. Infusion may be provided by vacuum assisted resin transfer moulding (VARTM), e.g. with the part element in an inclined position or a substantially horizontal position.
The method 300 comprises providing 302 a primary sheet, such as the primary sheet 80 of previous figures, having a primary first side and a primary second side.
The method 300 further comprises providing 304 a first fibre thread extending in a primary first direction and forming a first primary loop on the primary first side of the primary sheet. The loop is formed to extend from a primary first L1 point at the primary first side of the primary sheet to a primary first L2 point at the primary first side. Providing 304 the first fibre thread includes anchoring 306 the first fibre thread, such as a first end of the first fibre thread, to the primary sheet.
The method 300 comprises providing 308 a second fibre thread extending in a primary second direction and forming a second primary loop on the primary first side of the primary sheet. The loop is formed to extend from a primary second L1 point at the primary first side of the primary sheet to a primary second L2 point at the primary first side. Providing 308 the second fibre includes anchoring 310 the second fibre thread to the primary sheet.
The method 300 further comprises providing 312 a first pre-shaped element and positioning 314 the first pre-shaped element between the first fibre thread and the second fibre thread. Further pre-shaped elements may be provided and arranged on top of the first pre-shaped element, alongside the first pre-shaped element in the longitudinal direction, or alongside the first pre-shaped element in the transverse direction. The first pre-shaped element, and optionally any further pre-shaped elements, may be provided 312 after the first fibre thread and/or the second fibre thread has been provided 304, 308, as illustrated
The method 300 optionally comprises providing 316 a secondary sheet, such as the secondary sheet 100 as described with respect to previous figures. The method 300 may further comprise arranging 318 the secondary sheet and the primary sheet such that the primary first side of the primary sheet is facing the secondary second side of the secondary sheet.
Positioning 314 the first pre-shaped element may comprise positioning the first pre-shaped element between the primary sheet and the secondary sheet. The secondary sheet and the primary sheet may be arranged 318 prior to positioning 314 the first pre-shaped element, i.e. the first pre-shaped element may be positioned 314 after arranging 318 the secondary sheet and the primary sheet.
The secondary sheet may comprise a first primary sit and/or a second primary slit. The secondary sheet and the primary sheet may be arranged 318 such that the first primary slit is aligned with the first primary loop and/or such that the second primary slit is aligned with the second primary loop. The method 300 optionally comprises pulling 320 the first primary loop through the first primary slit and/or pulling 322 the second primary loop through the second primary slit.
The method 300 optionally comprises providing 324 a first fibre strip and pulling 326 the first fibre strip through the first primary loop of the first fibre thread and/or the second primary loop of the second fibre thread. The strip may be fastened or tightened to retain the pre-shaped elements.
The method 300 optionally comprises transferring 328 the part element, such as the primary sheet, the first pre-shaped element, and optionally the secondary sheet of the part element, from a first position to a second position. The first position may be a pre-form mould. The second position may be a mould for manufacturing for example a spar beam or a mould for manufacturing a blade shell part. Transferring 328 the part element may comprise attaching 330 a transportation structure to the first fibre thread and/or the second fibre thread, e.g. attaching the first primary loop and/or the second primary loop to hooks in the transportation structure.
Transferring 328 the part element may comprise arranging 332 the part element in a mould comprising an inclined surface, and wherein arranging the part element comprises aligning the part element on the inclined surface of the mould. Alternatively, the part element may be arranged 332 on a blade shell part in a blade shell mould.
The method 300 optionally comprises curing 334 the part element and/or a wind turbine blade part comprising the part element. For example, the part element may be impregnated and/or infused with resin and the resin may be cured. The part element may be cured in the first position, e.g. In the pre-form mould, or in the second position, e.g. In the mould or the blade shell mould.
The part element may be cured by infusing the part element with a resin. Infusion may be provided by vacuum assisted resin transfer moulding (VARTM), e.g. with the part element in an inclined position or a substantially horizontal position.
Exemplary embodiments are disclosed in the following items:
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 |
|---|---|---|---|
| 1910566.7 | Jul 2019 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2020/070565 | 7/24/2020 | WO |
