巴西专利BR112014014708B1 WIND TURBINE BLADES AND MANUFACTURING METHOD

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专利摘要:
"wind turbine blades and manufacturing method" for treating the present invention of a reinforcing structure 9 for a wind turbine blade in the form of an elongated stack 27 of layers 31 of pultruded fibrous composite strips supported within a channel U-shaped 28, the length of each of the layers 31 is slightly different to create a taper at the ends of the stacks; the center of the stack 27 has five layers 31, and each end has a single layer 31. The ends of each of the layers 31 are chamfered, and the stack is coated with a thin pultruded fibrous composite strip 33 extending across the along the entire length of the stack 27, the reinforcing structure 9 extends along a curved path within the outer shell of the blade. during configuration of the blade components within the mold 37, the reinforcing structure 9 is introduced into the mold 37 with the sliding of the channel 28 along the surface of an elongated wedge 29 within the mold 37 along the curved path . the wedge 29 is oriented along its length at an angle depending on the curvature of the path in this position, so as to guide the reinforcing structure 9 into the desired position. the blade outer skin regions on either side of the reinforcing structure 9 are filled with structural foam 17, and the reinforcing structure 9 and foam 17 are both sandwiched between an inner coating 18 and an outer coating 19.
公开号:BR112014014708B1
申请号:R112014014708-6
申请日:2012-12-11
公开日:2021-08-17
发明作者:Mark Hancock；Frank Hoelgaard Hahn；Chris Payne
申请人:Vestas Wind Systems A/S；
IPC主号:

专利说明:

Technical Field
[001] The present invention relates to wind turbine rotor blades and methods of manufacturing wind turbine blades. Fundamentals of the Invention
[002] A typical wind turbine is illustrated in Figure 1. The wind turbine 1 comprises a tower 2, a nacelle 3 mounted on top of the tower 2 and a rotor 4 operatively coupled to a generator 5 inside the nacelle 3. wind turbine 1 converts the kinetic energy of wind into electrical energy. In addition to generator 5, nacelle 3 accommodates the various components needed to convert wind energy into electrical energy and also the various components needed to operate and optimize the performance of wind turbine 1. Tower 2 supports the load represented by nacelle 3, by rotor 4 and by the other components of the wind turbine inside nacelle 3.
[003] The rotor 4 comprises a central hub 6 and three elongated rotor blades 7a, 7b, 7c of approximately flat configuration, which extend radially outward from the central hub 6. In operation, the blades 7a, 7b, 7c they are configured to interact with the passing air flow to produce a thrust that causes the central hub 6 to rotate around its longitudinal axis. Wind speed exceeding a minimum level activates rotor 4 and allows it to rotate within a plane substantially perpendicular to the wind direction. The rotation is converted into electrical energy by generator 5 which is normally supplied to the utility grid.
[004] A conventional rotor blade is produced from an outer shell and a hollow elongated inner spar of generally rectangular cross section. The stringer has the function of transferring the loads from the rotating blade to the hub of the wind turbine. Such loads include tensile and compression loads directed along the length of the blade, resulting from the circular movement of the blade and the resulting wind loads that are directed along the thickness of the blade, that is, from the windward side of the blade to the leeward side.
[005] An alternative type of rotor blade is known, which avoids the need for an internal spar by incorporating within the outer shell of one or more fibrous reinforcing structures of high tensile strength and extending along the direction. the length of the blade. Examples of such arrangements are described in EP 1 520 983 and WO 2006/082479. Other arrangements are also described in US 2012/0014804 and WO 201 1/088372.
[006] In these arrangements, pultruded fibrous strips of material are used. Pultrusion is a continuous process similar to extrusion, in which fibers are pulled through a liquid resin supply means and then heated in an open chamber in which the resin cures. The resulting cured fibrous material has a constant cross section, however, since the process is continuous, the material once formed can be cut to any arbitrary length. This process is particularly economical and is therefore an attractive option for the manufacture of reinforcing structures for wind turbine blades.
[007] The use of cured pultruded strips overcomes the problems associated with conventional arrangements, in which uncured fibers are introduced into a mold to form the parts of a wind turbine blade, in which there is a risk of the fibers becoming misaligned .
[008] In addition, the pultruded strips have the property of absorbing the extremely high bending moments that arise during the rotation of the blades of wind turbines.
[009] In the two known arrangements described above, a relatively large number of separate elements are used to form the reinforcing structure, and each element needs to be positioned individually within the shell structure.
[010] It would be desirable to provide a suitable reinforcement structure for a wind turbine blade of this alternative type, which is of simpler construction and, consequently, more economical to manufacture. Document WO2009/059604 describes a structural mesh for reinforcing the structure of a wind turbine blade, which can be formed by pultruded elements. WO2011/135306 describes a modular structural composite for a wind turbine beam.
[011] The document US 2009/0269392 describes a wind turbine blade comprising elongated structural elements formed from laminated fiber fabrics infiltrated with resin.
[012] However, in this arrangement the fiber fabrics are cured in place, which requires the fabrics to be carefully positioned and correctly oriented on the shell surface prior to molding.
[013] It would therefore be desirable to provide a wind turbine blade that overcomes, or at least mitigates, some or all of the above-described disadvantages of known wind turbine blades. Description of the Invention
[014] Therefore, according to a first aspect of the present invention, there is disclosed a wind turbine blade of generally hollow construction and formed of opposite first and second half-shells; each half-shell comprising an inner lining and an outer lining and first and second elongated reinforcing structures located between the inner and outer linings; each of the structures extending along the length direction of the blade and comprising a stack of layers; each stack having a thickness extending in a direction substantially perpendicular to the surface of the blade; each layer extending across a width of the respective stack, the width being perpendicular to the length direction of the blade and perpendicular to the thickness of the stack, and each layer comprising at least one precured pultruded composite fibrous strip; each half-shell also comprising core material located between the inner and outer skins and extending: (a) between the first and second elongated reinforcing structures; (b) the first reinforcing structure elongated towards a leading edge of the blade; and (c) the second reinforcing structure elongated towards a trailing edge of the blade; the wind turbine blade also comprising a first elongated mesh extending between the first half-shell reinforcement structure and the second half-shell reinforcement structure, and the second elongated mesh extending between the second half-shell reinforcement structure. first half-shell and the second reinforcing structure of the second half-shell.
[015] The stack works inside the wind turbine blade as a stringer cover. Preferably, the width of each stack extends within the blade, in use, in a generally chord direction within a plane substantially parallel to the blade surface. Preferably, in a cross-section oriented across the length direction of the blade, each stack is shaped like an oblong rectangle, in which the stack thickness is parallel to the shorter sides of the rectangle and the width of the rectangle is parallel to the longer sides of the rectangle.
[016] The mesh is elongated in the direction of the length of the blade. It extends in a transverse direction between at least one of the reinforcing structures of the first half-shell and at least one of the reinforcing structures of the second half-shell. As exemplified below, the blade may have two I-shaped or C-shaped meshes, each of which extends between one of the reinforcing structures of the first half-shell and one of the reinforcing structures of the second half-shell. In other embodiments, some of which are described below, the blade has a mesh with an X-shaped cross section, extending between two reinforcement structures of the first half-shell and two reinforcement structures of the second half-shell .
[017] The main technical advantage of providing at least two reinforcing structures of this type inside each half-shell arises from the curvature of the wind turbine blade. In order to obtain the desired curvature, the internal surfaces of the molds used to manufacture the half-shells are also curved, and this imposes a corresponding curvature on the internal and external linings during the molding process. Since the top and bottom surfaces of the piles are substantially flat, a space arises between the pile surfaces and the curved inner and outer linings, which will be filled with resin during molding. In order to optimize the strength of the resulting wind turbine blade, it is desirable to reduce the size of this space. With the present invention, this is achieved by providing at least two reinforcing structures within each half-shell, such that each structure can have a smaller width than would be necessary if only a single reinforcing structure were to be provided.
[018] The elongated reinforcing structures and the core material define contact edges that preferably are substantially perpendicular to the surface of the wind turbine blade. Such an arrangement is advantageous in that it allows the reinforcing structures to be manufactured at low cost. Furthermore, during the molding operation, it is possible to place the core material in the mold before the reinforcing structures, and to use the edges of the core material to assist in positioning the reinforcing structures in the mold. This would not always necessarily be possible if the contact edges of the reinforcing structures were not perpendicular. The perpendicular direction is also the direction of the thickness of the wind turbine blade.
[019] The wind turbine blade preferably also comprises, inside each half-shell, a precured web located between the outer shell and at least one of the elongated reinforcing structures. Additionally or alternatively, the wind turbine blade preferably also comprises, within each half-shell, a precured web located between the inner liner and at least one of the elongated reinforcing structures. In each case, the web can be fabricated from pre-cured resin and glass fabric. The blade preferably comprises, within at least one of the half-shells, a precured mesh located between the outer shell and a contact region of one of the elongated reinforcing structures and the core material. The blade preferably comprises, within at least one of the half-shells, a precured mesh located between the inner liner and a contact region of one of the elongated reinforcing structures and the core material.
[020] These meshes provide additional rigidity to the transition regions between the reinforcement structures and the core material. Additionally, the mesh effectively prevents the wrinkling of the inner and outer linings of the turbine blades, which could otherwise occur when there are spaces between the lower reinforcement structures and the core material, or when the thickness of the reinforcement structures is different from the core material thickness.
[021] The stack preferably has a substantially rectangular cross section along its length, and/or preferably a substantially constant width. Furthermore, the pultruded fibrous composite strips preferably have a substantially uniform cross-section.
[022] The formation of the reinforcement structure from a stack of layers makes it possible to form the entire reinforcement structure as a separate component, and then incorporate the entire reinforcement structure in a single operation.
[023] Furthermore, since pultruded fibrous composite strips are economical to manufacture, and can be easily cut to any desired length, the resulting reinforcing structure can be conveniently manufactured in this way at low cost.
[024] An additional advantage of this arrangement lies in the fact that it allows the adjustment of the thickness of the pile at any point along its length, in order to fit the desired thickness profile of the outer shell of the wind turbine blade, simply through the selection of the number of layers to be embedded in the stack at this point. For this reason it is possible to form the reinforcing structure with any desired thickness profile, which matches the taper shape of the wind turbine blade.
[025] In wind turbine blades it is usually desirable to provide a greater degree of reinforcement along the central section of the blade along the longitudinal axis of the blade, that is, the midway region between the root and tip of the blade, as this is the region in which the blade is exposed to the greatest tensile stresses. Therefore, a particular desirable thickness profile is one in which the center section of the reinforcing structure has the maximum thickness, and in which one or both end sections have the minimum thickness.
[026] It is preferable, therefore, that the layers inside the reinforcement structure have different lengths, in such a way that the thickness of the stack is conical in the direction of at least one end.
[027] In the simplest arrangement, in which each layer of the stack has square section ends, this will result in a stack having a gradual taper, the height of each step being the thickness of each layer. To reduce the concentration of stresses at the edges of the layers, it would be desirable for the thickness profile at the edge of the stack to be smoother. It is, therefore, preferred that at least one of the two ends of each layer be bevelled. In this way, the top surface of the stack can be produced smoother along its entire length.
[028] Still, unless the chamfer presents a sufficiently small angle, there will still be discontinuities in the gradient along the conical ends.
[029] To further increase softness, it is preferable that the pile also comprises a cover layer extending along the entire length of the pile. Such a cover layer may have a thickness which is substantially less than the thickness of the other layers within the stack, for example the cover layer may be a quarter the thickness of the other layers. This allows the cover layer to be flexible enough to "rest" on the top surface of the stack and thereby smooth out changes in the orientation of the bottom surface.
[030] For example, in the preferred embodiment, there are five layers inside each stack, and the thickness of each layer is approximately 4 mm, that is, between 3.5 mm and 4.5 mm, with the thickness of the cover layer is only approximately 1 mm, ie between 0.5 mm and 1.5 mm. The advantage of a 4mm thickness for each layer lies in the fact that the pultruded strips can be supplied in a roll.
[031] The width of each layer is preferably approximately 150 mm, that is, between 140 mm and 160 mm, as this width provides the necessary degree of edge stiffness to prevent substantial edge vibrations.
[032] Other execution modalities are considered, in which there can be as little as 4 layers or as much as 12 layers inside each stack.
[033] Each layer within the stack, other than the cover layer, when provided, may comprise a single pultruded fibrous composite strip extending over the entire width of the layer. An arrangement of this type has the advantage of simplicity and therefore low manufacturing cost, as only one strip is required inside each layer. Furthermore, since each layer within the stack has the same width, all pultruded and fibrous composite strips, other than the cover layer when provided, can be manufactured from the same pultrusion apparatus, or in turn may be cut from the same pultruded strip. Alternatively, each layer may comprise a parallel arrangement of a plurality of pultruded and fibrous composite strips. This can take the form of a first configuration, in which the lateral or longitudinal edges of the strips inside each layer of the stack are aligned with the lateral (longitudinal) edges of the strips in the other layers, in which case each strip will have a smaller width than in the above-mentioned arrangement, in which each layer comprises only one strip. However, the strips can still have the same width and therefore can be formed from the same pultrusion apparatus or cut from the same pultruded strip. In a second configuration, the inner (longitudinal) edges of the strips within each layer of the stack are staggered relative to the inner side edges of the strips within each adjacent layer. While this means that not all strips will be the same width and must consequently be formed from more than one pultrusion apparatus, this process can result in a more stable pile. In fact, such a configuration is usually found in a brick wall.
[034] In each of the arrangements described above in which each layer comprises more than one strip, the strips within each layer may alternatively, or additionally, be arranged end to end. This can be advantageous, for example, when the reinforcing structure is of substantial length, in which case manufacturing can be simplified by forming the reinforcing structure from a number of relatively short pultruded strips.
[035] It is important that the fibrous and pultruded composite strips have sufficient tensile strength, but they can be formed from fibers selected from: carbon fibers; glass fibers; aramid fibers; and natural fibers, including wood fibers and organic fibers, including combinations of any of these types of fibers. In the preferred embodiment, the pultruded fibrous composite strips are formed from carbon fibers embedded in a thermosetting resin matrix. Carbon fibers are particularly suitable because of their high strength-to-weight ratio compared to other fibers such as glass fibers.
[036] In a preferred embodiment, the reinforcing structure comprises an elongated support element to support the stack of layers. It assists in the process of moving the entire support structure, when formed, into the desired position inside the wind turbine blade. The preferred configuration of the support element consists of a channel having a generally U-shaped cross section, and in which the stack of layers is supported within the channel. This method is particularly convenient since the stack is substantially rectangular in cross section. It is especially preferred that at least the width of the U-shaped cross-section matches the width of the stack, as in this case the U-shaped side arms will prevent any unwanted lateral movement of the layers inside the stack during transport.
[037] The support element can be conveniently manufactured from a glass-reinforced plastic material (GRP) and can also both comprise and contain a conductor of electrical discharges.
[038] As mentioned above, the support element is preferably formed of a glass-reinforced plastic material (GRP) and may comprise a conductor of electrical discharges.
[039] The coatings are preferably manufactured from GRP.
[040] With this arrangement, each half-shell can be formed separately and then the two halves are joined together before the entire shell, with the reinforcing structures in position, is cured by heating.
[041] The inner and outer shells of the half-shells can be fabricated from a fiberglass epoxy resin composite.
[042] The wind turbine blade comprises at least two elongated webs located between the reinforcement structures inside the opposite half-shells, in order to transfer the shear forces acting on the wind turbine blade in use. A web of this type can therefore be referred to as a "shear web". The combination of two reinforcing structures of this type and the web emulates and has the structural advantages of an I-beam.
[043] In one embodiment, each shell comprises two reinforcement structures, and the elongated weft has an X-shaped cross section. In this case, each of the two diagonals of the X shape preferably extends between respectively two of the structures. reinforcement. Such an arrangement makes it possible for a single web to be used for four reinforcing structures.
[044] The X-shaped weft is preferably formed from two V-shaped wefts connected together, since the V-shaped wefts can be easily stacked or nested to facilitate storage and transport.
[045] In addition, the web is preferably made of a resilient material to more easily mold to the shape of the mold during the manufacture of wind turbine blades.
[046] The X-shaped resilient web is preferably fabricated slightly wider than the distance between the two half-shells, such that the web can flex to some extent when the half-shells are joined together. This method not only allows for greater tolerances in the size of the weft, but it also allows a good adhesiveness to be established between the weft and the half-shells. When the adhesive is cured, the weft is locked in the desired position, and the height of the weft coincides with the separation between the two half-shells.
[047] In this case, the weft preferably comprises a respective flange at each end of the two diagonals of the X-shaped cross section, in order to direct the shear force of the full width of each reinforcing structure to the weft.
[048] As an alternative to using an X-shaped weft, a conventional C-shaped weft can be provided, in which the two C-shaped arms can form flanges for coupling the weft between the blade half-shells .
[049] An additional weft having a Z-shaped cross section can also be used. This is particularly desirable when there are six reinforcing structures, as an X-shaped weft can be provided to absorb shear forces between four opposing reinforcing structures, typically within the leading edge of the blade, and the weft-shaped weft. Z can then be used to absorb the shear forces between the two remaining opposing reinforcing structures, typically within the trailing edge of the blade, i.e. positioned between the X-shaped weft and the trailing edge of the blade. The terms "front edge" and "rear edge" will be described in more detail below.
[050] In a preferred arrangement, four of the reinforcing structures extend in generally parallel directions along the length of the blade, with the two remaining reinforcing structures being shorter and extending away from the other reinforcing structures in the sections. wider blade to form "rear spars". The resulting separation of the reinforcing structures in the wide portions of the blade provides an improvement in edge stiffness. The provision of the rear spars also reduces the length of the unsupported blade shell between the main frame and the trailing edge, which in turn allows the structural foam inside the blade to be thinner. By retaining the separation between the reinforcing structures at the root end of the blade, the termination of the structures can be carried out with a reduced concentration of stresses.
[051] The upper and lower arms of the Z shape preferably serve as flanges for connecting the weft between the two outer half-shells of the blade, for example, with the application of a layer of adhesive on the exposed outer surfaces of the arms. Therefore, only the center section of the Z-shaped weft extends into the space between the associated reinforcing structures.
[052] In the case of an X-shaped weft, the X-shaped diagonals are preferably bent at the intersection, in such a way that the angle between two adjacent arms is different from the angle between the two other arms.
[053] Alternatively, the weft can have a Y-shaped cross section.
[054] In each case, the weft or wefts are preferably formed of a resilient material. This provides a specific benefit when the upper and lower half-shells are connected together with the wefts being in position between the half-shells, but physically coupled only to the lower half-shell, as in the junction of the two half-shells together , the free ends of the webs to which a layer of adhesive can be applied will exert a force against the upper half-shell sufficient to cause the free ends of the web to adhere to the upper half-shell.
[055] In all of the arrangements described above, the inner and outer skins preferably extend substantially uninterruptedly along the core material and reinforcing structures.
[056] A method of manufacturing a wind turbine blade of generally hollow construction and formed of opposite first and second half-shells may comprise constructing each half-shell from an inner shell and an outer shell; locating the first and second elongated reinforcing structures in the outer skin so as to extend along the length direction of the blade; each reinforcing structure comprising a stack of layers, each stack having a thickness extending in a direction substantially perpendicular to the surface of the blade; each layer extending across a width of the respective stack, the width being perpendicular to the length direction of the blade and perpendicular to the thickness of the stack, and each layer comprising at least one precured pultruded composite fibrous strip; placing within each half-shell the core material in the outer shell so as to extend: (a) between the first and second elongated reinforcing structures; (b) the first reinforcing structure elongated towards a leading edge of the blade; and (c) the second reinforcing structure elongated towards a trailing edge of the blade; placing the inner liner on the upper surface of the first and second elongated reinforcing structures and the core material; and placing an elongated web so as to extend between at least one of the reinforcing structures in the first half-shell and one of the reinforcing structures in the second half-shell.
[057] In one embodiment, the method comprises the manufacture of a wind turbine blade of the aforementioned type, in which one or more of the reinforcing structures extend at least partially along the length of the wind turbine blade and the along a respective predetermined curve defined by the outer profile of the wind turbine blade, the method comprising, for the or each reinforcing structure: providing an elongated and substantially rigid support surface within a mold, the support surface extending along the predetermined curve and which is oriented at each position along the predetermined curve at an angle which depends on the degree of curvature at that position, in order to facilitate the correct positioning of the reinforcing structure; inserting the support element into the mold; and positioning the reinforcing structure along the support surface.
[058] The step of positioning the reinforcing structure can be performed by sliding the support element along the support surface in the direction of the predetermined curve.
[059] With the proper orientation of the support surface, analogously to the slope of curved streets, the support element can be moved to the desired final position inside the mold by sliding it along the support surface. In this way, the support surface ends up acting as a directing or guiding surface for the reinforcing structure.
[060] It is preferable that the stack be positioned on the support element as a first step, and that the complete reinforcing structure is moved into position in this way, although it is obviously possible to move only the support element to the desired position inside of the mold as the first step, and then inserting the stack into the mold, for example, by sliding the stack along the support element. Alternatively it would also be possible to insert the individual layers of the stack into the mold one by one.
[061] The support surface may conveniently be a surface of an elongated wedge arranged in the mold surface. In this case, the wedge can be formed from structural foam.
[062] In a preferred embodiment, the wind turbine blade comprises at least one elongated reinforcing structure extending in the direction of the length of the wind turbine blade, a respective predetermined curve defined by the external profile of the wind turbine blade, and each reinforcement structure comprises a reinforcement element supported within a generally U-shaped cross-section channel, and the method comprises positioning each reinforcement structure within a mold.
[063] In this case, the channel can first be positioned inside the mold, and then the reinforcement element can be placed inside the channel. Alternatively, the reinforcement element can first be positioned within the channel, and then the entire reinforcement structure, i.e. the channel containing the reinforcement element, can then be positioned within the mold.
[064] A substantially rigid and elongated support surface may advantageously be provided within the mold, the support surface extending along the predetermined curve and being oriented at each position along the predetermined curve at an angle depending on the degree of curvature in this position, in order to facilitate the correct positioning of the reinforcement structure; and the method preferably comprises: introducing the reinforcing structure into the mold; and positioning the reinforcing structure along the support surface, for example, by sliding the support element along the support surface in the direction of the predetermined curve.
[065] The steps of introducing the pre-cured pile and the other structural elements can be performed in any desired sequence.
[066] Alternatively, the or each reinforcing structure can be constructed from the U-shaped channel, and the individual strips pultruded in place within the mold.
[067] Although in the preferred embodiment there are six reinforcement structures inside the wind turbine blade, there may obviously be a greater or lesser amount of reinforcement structures, depending on the size and/or shape of the wind turbine blade or the degree of reinforcement required.
[068] The invention also discloses a method of manufacturing a wind turbine blade of generally hollow construction and comprising first and second half-shells; arranging, on each of a first and second elongated half-mold, one or more fiber fabrics for the respective outer coverings; locating, in each of a first and second elongated half-mold, first and second elongated reinforcing structures in the fiber fabrics for the outer sheaths so as to extend along the length direction of the respective mold halves; each reinforcing structure comprising a stack of layers, each stack having a thickness extending in a direction substantially perpendicular to the surface of the respective mold half; each layer extending across the width of the respective stack, the width being perpendicular to the length direction of the respective mold half and perpendicular to the thickness of the stack, and each layer comprising at least one precured pultruded fibrous composite strip; arranging, within each respective mold half, the core material in the fiber fabrics for the outer sheath so as to extend: (a) between the first and second elongated reinforcing structures; (b) of the first reinforcing structure elongated towards a leading edge of the respective mold half; and (c) the second reinforcing structure elongated towards a trailing edge of the respective mold half; arranging, in each first and second elongated mold halves, on the upper surfaces of the first and second elongated reinforcing structures and core material, one or more fiber fabrics for the respective inner liners; supplying resin into the interior of the first and second mold halves; subsequently curing the resin to form the first and second half-shells; subsequently arranging a first elongated mesh and a second elongated mesh on one of the mold halves; and pivoting the first half-mold in a position above the second half-mold such that the first elongated mesh extends between the first strut structure of the first half-shell and the first strut structure of the second half-shell, and that the second elongated mesh extends between the second strut structure of the first half-shell and the second strut structure of the second half-shell.
[069] Preferably, the method comprises locating, within at least one of the mold halves, a precured mesh between the outer shell and a contact region of one of the elongated reinforcing structures and the core material. Preferably, the method comprises locating, within at least one of the mold halves, a precured mesh located between the inner liner and a contact region of one of the elongated reinforcing structures and the core material.
[070] The or each reinforcing structure can be formed and precured in a separate mold and then introduced, along with the other wind turbine blade components, into the main mold. With such an arrangement, it is possible to introduce the precured reinforcing structure into the main mold without using the U-shaped channels or wedge-shaped supports described above. Brief Description of Drawings
[071] In order for the present invention to be more easily understood, preferred embodiments of its execution will now be described with reference to the attached drawings, in which: - Figure 1 illustrates the main structural components of a wind turbine; Figure 2 shows a schematic illustration of the inner surface of one half of the outer shell of a wind turbine blade incorporating reinforcing structures according to a preferred embodiment of the present invention; Figures 3(a) and 3(b) show cross-sectional sketches of arrangements of reinforcing structures within a half-shell of a wind turbine blade; Figures 4(a) to 4(b) show schematic longitudinal cross-sectional views of a wind turbine blade incorporating the reinforcing structures shown in Figure 2; Figure 5 illustrates a side cross-sectional view of part of one of the reinforcement structures illustrated in Figure 2; - Figures 6(a) to 6(c) illustrate longitudinal sections of three different embodiments of the reinforcement structures according to the present invention; Figures 7(a) and 7(b) show two schematic representations of an X-section frame, according to a preferred embodiment, in different positions along the length of a wind turbine blade; Figure 8 illustrates a longitudinal cross-sectional view of a reinforcing structure mounted inside a mold during the manufacture of a wind turbine blade according to a preferred embodiment; - Figures 9(a) and 9(b) illustrate a method of manufacturing a wind turbine blade according to a preferred embodiment of the present invention: - Figures 10(a) to 10(f) show alternative forms of frames, according to other embodiments, shown in different positions along the length of a wind turbine blade; Figures 11(a) and 11(b) illustrate other alternative forms of wefts, according to embodiments of the present invention; Figure 12 shows a flowchart illustrating the steps of manufacturing a wind turbine blade according to a preferred embodiment of the present invention; Figure 13 illustrates an alternative method of manufacturing a wind turbine blade according to an embodiment of the present invention; - Figure 14 shows a flowchart illustrating the steps of the method shown in Figure 12; Figures 15(a) to 15(c) illustrate a preferred embodiment in which meshes are provided on each half-shell of the wind turbine blade. Detailed Description of the Invention
[072] During the following description of the preferred embodiments of the present invention, and in the drawings, the same reference numbers are used to indicate the same or corresponding structural characteristics.
[073] Referring to Figure 2, a half 8 of the outer shell of a wind turbine blade is formed with three elongated reinforcing structures 9, 10, 11, to be described in more detail below. Two of the reinforcing structures 9, 10 extend substantially along the entire length of the wind turbine blade, from root section 12 to blade tip 13. Blade root section 12 is formed with threaded metal inserts 14 for receiving screws with which the blade is coupled to the central hub of the wind turbine, as described above with reference to Figure 1.
[074] The third reinforcing structure 11 extends only partially along the blade from the root section 12, being also laterally displaced from the other two reinforcing structures 9, 10 towards the trailing edge 15 of the blade and away from the leading edge 16 of the blade.
[075] The two bracing structures 9, 10 form the wind turbine blade spar covers and the third bracing structure 11 acts as a stiffener for the trailing edge 15.
[076] The ends of the three reinforcing structures 9, 10, 11 within the 12 root section of the blade are encased in a glass-reinforced plastic (GRP) material to add strength and stability, as are the distal ends of the two reinforcing structures. reinforcement 9, 10 that extend to the tip of the blade 13.
[077] The remaining portions of the outer shell are filled with structural foam 17, and the reinforcing structures 9, 10, 11, and structural foam 17 are all formed within an outer shell and an inner shell to be further described. details below.
[078] Structural foam 17 consists of a lightweight core material, and it should be understood that other core materials may also be used, such as wood, particularly balsa wood, and honeycomb structures.
[079] The complete turbine blade is formed from the upper half 8 of the outer shell shown in Figure 2, along with a corresponding lower half and two inner webs.
[080] Figures 3(a) illustrate a cross-sectional view of a conventional arrangement, in which each half-shell 8' comprises an inner liner 18' and an outer liner 19' between which only a single reinforcing structure 9 'is provided. The regions between inner cladding 18' and outer cladding 19' on each side of the reinforcing structure 9' are filled with structural foam 17'. As can be seen from the drawing, there is significant curvature across the width of the 8' half-shell. Since the reinforcing structure 9' is formed with a substantially regular cross section, it follows that substantial voids 20' are formed between the outer shell 19' and the central region of the reinforcing structure 9', and between the shell. internal 18' and the end regions of the reinforcing structure 9'. During the molding step, to be described in more detail below, said resin is introduced into these 20' voids, which is undesirable in a composite structure, as it increases both the weight and cost of the blade, and can also cause structural problems .
[081] Figure 3(b) illustrates a cross-sectional view of a preferred embodiment of the present invention, in which each half-shell 8 is equipped with at least two reinforcing structures 9, 10 provided between the inner liner 18 and the outer shell 19. As can be seen, the volume of the resulting voids 20 that are formed between the outer shell 19 and the central region of the gusset structure 9, and between the inner shell 18 and the end regions of the gusset structure 9 is substantially smaller than the voids 20' that occur when only a single reinforcing structure is provided. As a result, the amount of resin needed to fill the voids 20 during the molding process is substantially less.
[082] Additionally, with the use of two reinforcing structures in each half-shell, as shown in Figure 3(b), as opposed to the single reinforcing structure shown in Figure 3(a), the overall widths of the reinforcing structures they are located closer to the outer casing 19 of the wind turbine blade. This is advantageous for structural reasons, as it provides a higher second moment of inertia so that the wind turbine blade has greater resistance to torsionalism.
[083] Figures 4(a) to 4(e) illustrate cross-sectional representations of the complete wind turbine blade in different positions along the length of the blade. Figure 4(a) represents the blade close to the tip of the blade 13, from which it can be seen that only the first two reinforcing structures 9, 10 are present in this position along the length of the upper half of said outer shell shown in Figure 2. The lower half 21 of the outer shell is also equipped with three reinforcing structures 22, 23, 24, and again only two of which 22, 23 are present in this position.
[084] An elongated and resilient web 25 fabricated from a layer of balsa wood or lightweight foam sandwiched between two outer layers of GRP and having a generally X-shaped longitudinal cross section is provided within the outer shell and serves to transfer the shear forces acting on the blade of the wind turbine in use. One of the two diagonal arms of the X shape extends between a first pair of reinforcement structures 9, 23, and the other diagonal arm extends between a second pair of reinforcement structures 10, 22.
[085] In Figure 4(b), which represents a position along the length of the turbine blade between that of Figure 4(a) and the center section, the end portions of the two remaining reinforcing structures 11, 24 can be views.
[086] Figure 4(c) represents the central section of the turbine blade, from which it can be seen that another elongated and resilient web 26 having a generally Z-shaped longitudinal cross section is provided, which extends between the two reinforcing structures 11, 24 on the trailing edge 15 of the blade. The two outer Z-shaped edges act as flanges to connect the Z-shaped weft 26 to the two associated reinforcing structures 11, 24.
[087] With reference to Figure 4(d), which consists of a detail of the cross-sectional view of Figure 4(c), the reinforcing structure 22 is sandwiched between the inner shell 18 and the outer shell 19, and the parts remainders of the outer shell are formed from a layer of structural foam 17, also sandwiched between the inner and outer shells 18, 19. The shells are manufactured from GRP.
[088] The reinforcing structure 22 is in the form of a stack 27 of layers of fibrous and pultruded composite strips supported within a U-shaped channel 28, which in turn is supported on an elongated wedge 29 in such a way that the base of the channel 28 is at an acute angle to the outer shell 19 of the shell. Channel 28 includes a material that acts as a conductor of electrical discharges in use. In other embodiments, the U-shaped channel 28 and wedge 29 can be omitted.
[089] The end of the X25 shaped weft arm is equipped with a flange 30 to direct the applied shear force across the entire width of the reinforcing structure 22 to the X25 shaped weft.
[090] It will be appreciated that the enlarged view shown in Figure 4(d) applies equally to each of the six reinforcing structures 9, 10, 11, 22, 23, 24.
[091] Figure 4(e) illustrates a cross-sectional view of the blade between the central section shown in Figure 4(c) and the root section 12, and it can be seen that the reinforcing structures 9, 10, 11, 22 , 23, 24 inside each half-shell are closer together than in the central section of the blade, reflecting the curvature of the reinforcing structures.
[092] In Figures 4(a) to 4(e) it can be seen that the reinforcing structures 9, 10, 22 and 23 consist of stringer covers which, together with the shear webs 25, form the main structural stringer of the wind turbine blade. Reinforcement structures 11 and 24 which are located at the trailing edge stiffen the wind turbine blade in the region of the trailing edge to provide stability against warping and, together with the weft 26, form a trailing edge spar.
[093] Each of the piles 27 of the reinforcement structures 9, 10, 11, 22, 23, 24 has a conical shape longitudinally at both ends. This is achieved by reducing the number of layers of pultruded fiber strips from five in the central region to just a single layer at each end. This feature is indicated in the drawings, in which, in Figures 4(a) and 4(e), the respective piles 27 of the reinforcement structures 9, 10, 22, 23, 24 have only a single layer, while the stacks 27 within the center section illustrated in Figure 4(c) have five layers. Also, in Figure 4(b), the stacks 27 of the reinforcing structures 9, 10, 22, 23 at the ends of the X 25-shaped weft have five layers, while the stacks 27 of the reinforcing structures 11, 24 at the ends of the Z-shaped weft 26 have only a single layer.
[094] This feature allows reinforcing structures 9, 10, 11, 22, 23, 24 to adopt a profile consistent with the thickness profile of the outer shell of the blade.
[095] This feature is further illustrated in the side cross-sectional view of Figure 5, which shows how the thickness of the five-layer stack 27 31 is tapered towards the root end 12 and the distal end 32. It should be emphasized that the drawing is merely illustrative of the tapered arrangement: in practice the taper can be distributed over a large part of the length of the reinforcing structure.
[096] Two other features of the preferred mode of execution improve the smoothness of the taper, in order to reduce the impact of stresses that could arise due to discontinuities in the surface profile of the stack 27. First, each of the layers 31 is chamfered in both ends so as to remove the square cut edges that are formed during cutting of the pultruded strips that form the layers 31. Second, the stack 27 is covered with a top layer 33 formed from a fibrous composite strip and additional pultruded having a thickness less than that of the lower layers 31. Since the top layer 33 is thinner than the other layers 31, it is also more flexible and therefore also has the ability to fold around. of the bevelled angled ends of the stack 27 into the tapered end regions to form a relatively smooth top surface.
[097] Each of the layers 31 inside the stack has a thickness of approximately 4 mm, and the thickness of the top layer is approximately 1 mm.
[098] Figures 6(a) to 6(c) consist of longitudinal cross-sectional views showing three different arrangements of fibrous and pultruded composite strips, or pultrusion strips 34 within the five layers 31. In Figure 6(a) , each layer 31 has only a single pultrusion strip 34 within each layer. In Figure 6(b), each layer 31 is formed from a parallel arrangement of three pultrusion strips 34 of equal width placed together and side by side. In Figure 6(c), each layer 31 has either three or four pultrusion strips 34 in a parallel side-by-side arrangement, but containing pultrusion strips 34 of two different widths.
[099] In preferred embodiments, each of the pultrusion strips 34 located within the three arrangements described above extends the full length of the respective layer 31, although it may be beneficial in some embodiments to have at least some of the layers 31 include shorter strips 34 that are arranged end to end.
[0100] Figures 7(a) and 7(b) illustrate in more detail the central section and the root section 12, respectively, of the wind turbine blade showing the resilient web shaped like an X 25. The reinforcing structures are not shown in the drawings for the sake of clarity. The weft is formed of two halves generally V-shaped, 25a, 25b, and the lower ends of each of the halves 25a, 25b, as can be seen in the drawings, is coupled to the lower half of the outer shell with the aid of a adhesive layer (not shown), and the two halves 25a, 25b of the weft 25 are joined together by screws 36.
[0101] Figure 8 consists of a longitudinal cross-sectional view illustrating in more detail the region of the outer shell that includes a reinforcing structure 22 inside a lower half-mold 37. During manufacture, the outer coating 19, in the form of a dry fiber fabric, or a plurality of superimposed and/or overlapping dry fiber fabrics, is first placed on the surface of the mold half 37, and elongated wedges 29 are then positioned in said outer casing 19 along the curvilinear regions in which the reinforcing structures 9, 10, 11, 22, 23, 24 are to be positioned. The liner, described below, is also formed from a dry fiber fabric, or from a plurality of superimposed and/or superimposed dry fiber fabrics. The dried fabrics are, once positioned in the mold halves with other components as described below, impregnated with the resin supplied to the interior of the mold halves, for example, in an infusion process such as the process described below. It should be noted that as an alternative, also mentioned below, the internal and external coating can be supplied from prepreg fabrics (pre-impregnated fiber), with the resin being supplied to the interior of the mold halves together with the fiber material of the fabrics.
[0102] The reinforcement structures are positioned along the respective upper surfaces of the wedges 29. This can be achieved by first positioning the U-shaped channel 28 of each reinforcement structure along the upper surface of the wedge 29 and then inserting the stack 27 of pultruded fibrous composite strips in channel 28, or alternatively forming the entire reinforcing structure outside the half-mold 37 and then positioning it along the upper surface of wedge 29. In each case, the structure gussets can be lowered into position on wedge 29 or slid into position along the surface of wedge 29.
[0103] The orientation of the upper surfaces of the wedges 29 is varied along its length depending on the curvature of the linear regions, in order to retain the reinforcement structures in the desired positions.
[0104] A layer of structural foam 17 is then introduced inside the mold half 37 to fill the regions between the reinforcing structures 9, 10, 11, 22, 23, 24. The inner liner 18, in the form of a fabric of dry fibers, or of a plurality of superimposed and/or superimposed dry fiber fabrics, is then placed on the upper surfaces of the reinforcing structures, and the structural foam 17 and components are covered with an airtight pocket to form a chamber of evacuation which is subsequently evacuated and resin introduced, as described in more detail below.
[0105] The components located inside the lower half-mold 37 are then heated and the resin therewith cured so as to form the lower outer shell of the blade.
[0106] The inner lining 18 and the outer lining 19 are formed, in this embodiment, from a layer of biax glass fabric, although multiple layers may alternatively be used. As mentioned above, it would also be possible to omit the U-shaped channel 28 and the elongated wedges 29, causing the stack 27 to be formed and located directly on the outer shell 19. It would also be possible to position the structural foam 17 on the outer shell 19 and then subsequently inserting the battery 28 into the mold 37.
[0107] An upper half-mold with an outer shell is then positioned above the lower half-mold 37 so as to form the complete outer shell of the blade.
[0108] Figure 9(a) illustrates the general structure of the components of the lower half of the outer shell when located in the lower mold half 37. Referring to Figure 9(b), after the inner liner 18 has been placed over the surface of the reinforcing structures 22, 23 and the upper surface of the structural foam 17, a hermetic sealing bag (i.e., a vacuum bag) 38 is then coupled to the mold to form an evacuation chamber encapsulating all components, and then the chamber is evacuated using a vacuum pump 39. With the pump 39 still energized, a supply of liquid resin 40 is connected to the chamber in order to infuse both the components and the interstitial spaces between them. A corresponding infusion process is applied to the components of the upper half of the outer shell. Said pump 39 continues to operate during a subsequent molding operation, in which the mold is heated in order to cure the resin, although during the curing process the intensity of depressurization can be decreased.
[0109] The X 25 shaped web and the 26 Z shaped web are then affixed using an adhesive to the inner liner 18 immediately above the reinforcing structures 22, 23, 24 within the lower mold half 37 , and the upper free ends of the webs 25, 26 are painted with respective layers of adhesives.
[0110] The upper half-mold is then pivoted to the position above the lower half-mold 37, and the two half-molds are connected together. This causes the reinforcing structures 9, 10, 11 within the upper mold half to stick to the upper free ends of the wefts 25, 26. The resilient nature of the wefts, 25, 26 causes a biasing force to arise in the wefts. 25, 26 against the upper reinforcing structures 9, 10, 11 in order to ensure good adhesion. The leading edge of the blade is formed along the leading edges of the respective half-molds, and the edge of the blade is formed along the trailing edges of the respective half-molds.
[0111] The mold is then opened, and the finished turbine blade is removed from the mold.
[0112] Figures 10(a) to 10(f) show cross-sectional illustrations of alternative execution modalities of wind turbine blades in which each of the frames 41, 42, 43 has an I-shaped cross section, the which, in combination with the associated reinforcing structures, result in an I-beam construction. Since each of the webs is equipped with a flange 30 at each end, these can alternatively be considered as C-section webs, where the C-shaped arms constitute the flanges 30.
[0113] In Figures 10(a) to 10(c), there are only four reinforcing structures 9, 10, 22, 23. Figure 10(a) represents a cross-sectional view near the tip of the blade, Figure 10 (b) a cross-sectional view halfway along the blade, and Figure 10(c) a cross-sectional view near the root end, in which it can be seen that the thickness of the reinforcing structure 9, 10, 22 , 23 is conical. As can be seen from the drawings, the reinforcing structures inside each half-shell are closer to the tip of the blade.
[0114] In Figures 10(a) to 10(f), there are six reinforcement structures 9, 10, 11, 22, 23, 24, and a respective I-shaped frame, 41, 42, 43 connecting each pair of opposing structures 9, 19; 10, 23; and 11, 24. Figure 10(d) represents a cross-sectional view near the tip of the blade, Figure 10(e) a cross-sectional view midway along the blade, and Figure 10(f) a seen in cross section near the root end in which again it can be seen that the thickness of the reinforcing structure 9, 10, 22, 23 is conical.
[0115] Figures 11(a) and 11(b) illustrate two other forms of a weft. In Figure 11(a), weft 44 has an X-shaped cross section in which the two diagonals are bent at intersection 45, such that the upper edges diverge at an angle α that is greater than the angle β between the two bottom edges. An advantage of this arrangement is that the wide upper angle allows for additional flexibility when the two half-molds are closed, while the lower edges merely serve to close the space between the two shells. In Figure 11(b), the two lower edges have been combined into a single edge, resulting in a weft 46 with a Y-shaped cross section. A weft of this type can replace the X-shaped and/or Z-shaped wefts described above.
[0116] With reference to Figure 12, the method described above can be summarized as comprising a step 47 of placing the support surface inside the lower mold half 37, a step 48 of introducing reinforcing structures 9 into the middle - lower mold 37 and a step 49 of sliding the reinforcing structures 9 along the surface of the wedge 29 to the respective desired positions.
[0117] Figure 13 illustrates an alternative method, in which the pultruded strips 34 are placed in a separate mold, equipped with a U-shaped channel 28, outside the main mold half 50, along with a die (resin or adhesive) which is precured in such a way that the stack 27 is formed in a separate mold 28. The precured stack 27 is then placed in the main mold half 50 for a resin infusion process together with other structural members.
[0118] Referring to Figure 14, this method can be summarized as comprising the following steps: (a) forming a stack of fibrous layers 51; (b) precuring the stack of fibrous layers in a first mold 52; (c) introducing the precured pile into a second mold 53; and (d) integrating the stack and other structural elements together within the second mold 54. In some embodiments, the stack may be partially cured in the first mold and then fully cured in the second mold. In other embodiments the stack can be fully cured in the first mold and integrated as such with other structural elements in the second mold in which some of the other structural elements are cured.
[0119] Figures 15(a) to 15(c) schematically illustrate another preferred embodiment, which can be combined with any of the embodiments described above. In order to improve clarity, elements were not drawn to scale. In each half-shell 8, precured inner and outer meshes 55, 56 are provided formed of glass fabric and precured resin, and these are positioned between the respective inner and outer linings 18, 19 and the structures gussets 9, 10. The meshes 55, 56 extend over the regions in which the lower gussets 9, 10 touch the core material 17. In the region of the blade tip 13, the two gussets 9, 10 are closely separated, as illustrated in the cross-sectional view of Figure 15(a) taken along line A - A' of Figure 15(c). In this case, each of the inner and outer mesh 55, 56 extends through both lower reinforcement structures 9, 10, so as to cover all four transition regions between the reinforcement structure 9, 10 and the core material. 17. However, in the region of the root section 12 of the blade, the two reinforcing structures 9, 10 are further apart, as illustrated in the cross-sectional view of Figure 15(b) taken along line B - B' of Figure 15(c). In this case, each of the inner and outer mesh 55, 56 extends through only one respective one of the lower reinforcement structures 9, 10, so as to cover only the two transition regions between the respective reinforcement structure, for example 9, and the adjacent core material 17.
[0120] The function of the internal and external mesh 55, 56 is to prevent the internal and external linings 17, 18 from suffering the effects of wrinkling caused by: (a) spaces between the lower reinforcement structures 9, 10 and the material of adjacent core 17; and (b) any slight differences between the thickness of the lower reinforcing structures 9, 10 and the thickness of the core material 17.
[0121] Figure 15(c) represents a plan view of this arrangement, from which it can be seen that the meshes 55, 56 form an approximate V-shape. The outer lines of the reinforcing structures 9, 10 are sandwiched between the inner and outer meshes 55, 56, as illustrated in the drawing by the dashed line. The side edges of the inner and outer mesh 55, 56 extend approximately 20 mm over the lower core material. It would also be possible to use a single precured mesh 55 located below the reinforcing structures 9, 10 and the core material 17. However, in practice it is beneficial for deposition that, for example, the inner and outer layers 17, 18 of the reinforcing structures 9, 10 and of the foam 17, are symmetrical about a central point of the plane of deposition.
[0122] It should be understood that numerous variations in the embodiments described above can be carried out without departing from the scope of the present invention, which is defined only by the following claims. For example, although in the preferred embodiment there are six gussets and both an X shaped and a Z shaped frame, alternative embodiments may comprise only four gussets and a single X shaped frame.
[0123] In another example, as opposed to using the resin infusion method for blade manufacturing described above with reference to Figure 9(b), fibers that are pre-impregnated with resin (ie, "pre-preg" fibers ") can be used for internal and external coatings, in which case it will not be necessary to infuse resin into the shell construction. In this arrangement, layers of adhesive films can be provided between the individual layers of the stack so that they stick together when the structure is cured.

权利要求:
Claims (14)
[0001]
1. WIND TURBINE BLADE, having a generally hollow construction and formed of opposite first and second half-shells; each half-shell (8) comprising an inner shell (18) and an outer shell (19) and first and second elongated reinforcing structures (9, 10, 22, 23) located between the inner and outer shells; each of the reinforcing structures (9, 10, 22, 23) extending along the length direction of the blade and comprising a stack (27) of layers (31); each stack (27) having a thickness extending in a direction substantially perpendicular to the surface of the blade; each layer (31) extending across a width of the respective stack (27), the width being perpendicular to the direction of the length of the blade and perpendicular to the thickness of the stack, and each layer comprising at least one pre-cured pultruded composite fibrous strip (34); each half-shell (8) also comprising a core material (17) located between the inner (18) and outer (19) linings and extending: (a) between the first (9, 22) and the second (10, 23) elongated reinforcing structures; (b) of the first reinforcing structure elongated towards a leading edge (16) of the blade; and (c) the second reinforcing structure elongated towards a trailing edge (15) of the blade; characterized in that the wind turbine blade also comprises a first elongated mesh (41) extending between the first reinforcing structure (9) of the first half-shell and the first reinforcing structure (22) of the second half-shell., and a second elongated mesh (42) extending between the first reinforcing structure (10) of the first half-shell and the second reinforcing structure (23) of the second half-shell.
[0002]
2. A BLADE according to claim 1, characterized in that the elongated reinforcing structures (9, 10, 22, 23) and the core material (17) define contact edges that are substantially perpendicular to the surface of the blade of the wind turbine.
[0003]
3. BLADE according to any one of the preceding claims, characterized in that it also comprises, inside each half-shell, a pre-cured mesh (56) located between the outer coating (19) and at least one of the reinforcement structures elongated (9, 10, 22, 23).
[0004]
4. BLADE according to any one of the preceding claims, characterized in that it also comprises, inside each half-shell, a pre-cured mesh (55) located between the inner lining (18) and at least one of the reinforcement structures elongated (9, 10, 22, 23).
[0005]
5. BLADE according to any one of the preceding claims, characterized in that it also comprises, inside each half-shell, a pre-cured mesh (56) located between the outer coating (19) and a contact region of a the elongated reinforcing structures (9, 10, 22, 23) and the core material (17).
[0006]
6. BLADE according to any one of the preceding claims, characterized in that it also comprises, inside each half-shell, a pre-cured mesh (55) located between the inner lining (18) and a contact region of a the elongated reinforcing structures (9, 10, 22, 23) and the core material (17).
[0007]
7. BLADE according to any one of the preceding claims, characterized in that the layers (31) have different lengths in such a way that the thickness of the stack (27) is conical towards at least one end.
[0008]
8. BLADE according to claim 7, characterized in that at least one of the two ends of each layer (31) is bevelled.
[0009]
9. A BLADE according to any one of the preceding claims, characterized in that each layer (31) comprises a single pultruded fibrous composite strip (34) extending across the entire width of the layer.
[0010]
10. BLADE according to any one of claims 1 to 8, characterized in that each layer (31) comprises a plurality of fibrous and pultruded composite strips (34).
[0011]
11. BLADE according to any one of the preceding claims, characterized in that the stack (27) also comprises a cover layer (33) extending the entire length of the stack, wherein the thickness of the cover layer is substantially smaller than the thickness of the other layers inside the stack.
[0012]
12. BLADE according to any one of the preceding claims, characterized in that the fibrous and pultruded composite strips (34) are formed from fibers selected from: carbon fibers; glass fibers; aramid fibers; and natural fibers, including wood fibers and organic fibers.
[0013]
13. BLADE according to any one of the preceding claims, characterized in that the inner and outer coatings (18, 19) extend substantially uninterrupted through the core material (17) and the reinforcing structures (9, 10, 22 , 23).
[0014]
14. METHOD OF MANUFACTURING A WIND TURBINE BLADE of generally hollow construction and comprising a first and a second half-shell, characterized in that it comprises the steps of: placing, in each one of a first and second elongated half-mold, from one or more fiber fabrics to the respective outer coverings (19); positioning, on each of the first and second elongated mold halves, a first and second elongated reinforcing structures (9, 10, 22, 23) in the fiber fabrics for the outer sheaths so as to extend along the direction. the length of the respective mold halves; each reinforcing structure (9, 10, 22, 23) comprising a stack (27) of layers (31), each stack having a thickness extending in a direction substantially perpendicular to the surface of the respective mold half; each layer (31) extending across the width of the respective stack (27), the width being perpendicular to the length direction of the respective mold half and perpendicular to the thickness of the stack, and each layer comprising at least one pre-pultruded fibrous composite strip -cured (34); placing within each respective mold half of the core material (17) in the fiber fabrics for the outer covering (19) so as to extend: (a) between the first (9, 22) and the second reinforcement structures (10, 23) elongated; (b) of the first reinforcing structure elongated towards a leading edge of the respective mold half; and (c) the second reinforcing structure elongated towards a trailing edge of the respective mold half; placing, on each of a first and second elongated half-mold, on the upper surfaces of the first and second elongated reinforcing structures and the core material, one or more fiber fabrics for the respective inner liners (18); supplying resin (40) into the first and second mold halves; subsequently curing the resin (40) to form the first and second half-shells; subsequently placing a first elongated weft (41) and a second elongated weft (42) in one of the mold halves; and pivoting the first half-mold into a position above the second half-mold so that the first elongated web (41) extends between the first reinforcing structures (9) of the first half-shell and the first reinforcing structure ( 22) of the second half-shell and the second elongated weft (42) extends between the second reinforcing structure (10) of the first half-shell and the second reinforcing structure (23) of the second half-shell.

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同族专利:

公开号 | 公开日

EP2791500B1|2019-03-06|

EP3505751B1|2021-03-24|

BR112014014708A2|2021-04-20|

DK2791500T3|2019-04-23|

CA2858397A1|2013-06-20|

EP2791500A1|2014-10-22|

CN104114856A|2014-10-22|

GB201121649D0|2012-01-25|

ES2719302T3|2019-07-09|

US20200049128A1|2020-02-13|

CA2858397C|2016-09-20|

US20140301859A1|2014-10-09|

EP3859143A1|2021-08-04|

WO2013087078A1|2013-06-20|

JP2015500942A|2015-01-08|

KR20140110951A|2014-09-17|

JP6105619B2|2017-03-29|

US10487797B2|2019-11-26|

ES2869238T3|2021-10-25|

GB2497578A|2013-06-19|

EP3505751A1|2019-07-03|

DK3505751T3|2021-04-19|

KR101642066B1|2016-07-29|

GB2497578B|2015-01-14|

CN104114856B|2016-12-07|

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法律状态:
2018-02-06| B25G| Requested change of headquarter approved|Owner name: VESTAS WIND SYSTEMS A/S (DK) |

2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

2020-02-04| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

2021-06-01| B350| Update of information on the portal [chapter 15.35 patent gazette]|

2021-07-06| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

2021-08-17| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 11/12/2012, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

申请号 | 申请日 | 专利标题

GB1121649.6|2011-12-16|

GB1121649.6A|GB2497578B|2011-12-16|2011-12-16|Wind turbine blades|

US201261588247P| true| 2012-01-19|2012-01-19|

US61/588,247|2012-01-19|

PCT/DK2012/050458|WO2013087078A1|2011-12-16|2012-12-11|Wind turbine blades|

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