FIBER-REINFORCED COMPOSITE BLANK, FIBER-REINFORCED COMPOSITE COMPONENT, ROTOR BLADE ELEMENT, ROTOR BLADE AND WIND TURBINE AND METHOD FOR PRODUCING A FIBER-REINFORCED COMPOSITE BLANK AND METHOD FOR PRODUCING A FIBER-REINFORCED COMPOSITE COMPONENT

Abstract

A fiber-reinforced composite blank for a fiber-reinforced composite component, in particular for a fiber-reinforced composite component of a wind turbine, comprising a layered construction with a form core consisting of or comprising a form core material, and a fiber layer adjoining the form core, said fiber layer consisting of or comprising a fiber layer material, and a plurality of reinforcing rods introduced into the form core and consisting of or comprising a reinforcing material, wherein the reinforcing material has a higher stiffness than the form core material. In this arrangement, the plurality of reinforcing rods is introduced into the form core at an angle to a form core plane. Furthermore, at least one reinforcing rod of the plurality of reinforcing rods is introduced into the form core at an angle to a direction orthogonal to the form core plane.

Claims

1. A fiber-reinforced composite blank for a fiber-reinforced composite component for a fiber-reinforced composite component of a wind turbine, comprising: a layered construction comprising: a form core comprising a form core material, and a fiber layer adjoining the form core, the fiber layer comprising a fiber layer material, and a plurality of reinforcing rods in the form core and comprising a reinforcing material, wherein the reinforcing material has a higher stiffness than the form core material, wherein the plurality of reinforcing rods are in the form core at an angle relative to a form core plane, and wherein at least one reinforcing rod of the plurality of reinforcing rods is in the form core at an angle relative to a direction orthogonal to the form core plane.

2. The fiber-reinforced composite blank as claimed in claim 1, wherein the plurality of reinforcing rods extend completely or partially through the form core.

3. The fiber-reinforced composite blank as claimed in claim 1, wherein the plurality of reinforcing rods have a maximum diameter of 5 mm (millimeters).

4. The fiber-reinforced composite blank as claimed in claim 1, wherein the form core material comprises at least one of polyethylene, polyvinylchloride, balsa wood, or foam.

5. The fiber-reinforced composite blank of claim 1, wherein the reinforcing material comprises a matrix material and a plurality of fibers embedded in the matrix material.

6. The fiber-reinforced composite blank as claimed in claim 1, wherein: each of the plurality of reinforcing rods introduced into the form core define a location of introduction on a surface of the form core, the surface of the form core has a plurality of locations of introduction, and wherein each of the plurality of locations of introduction define a region of introduction, and a first region of introduction is spaced apart from a second region of introduction.

7. The fiber-reinforced composite blank as claimed in claim 1, wherein at least two reinforcing rods of the plurality of reinforcing rods are introduced into the form core at different angles to the form core plane.

8. The fiber-reinforced composite blank as claimed in claim 1, wherein a maximum of two of three reinforcing rods of the plurality of the reinforcing rods lie in one reinforcing plane in the form core.

9. A fiber-reinforced composite component, comprising the fiber-reinforced composite blank as claimed in claim 1, and a cured matrix material, wherein at least portions of the plurality of reinforcing rods and the form core are embedded in the cured matrix material and form a composite, and wherein the cured matrix material binds the composite to the fiber layer.

10. A rotor blade element for a rotor blade, wherein the rotor blade element comprises at least one fiber-reinforced composite component as claimed in claim 9.

11. A rotor blade for a wind turbine, comprising at least one rotor blade element as claimed in claim 10.

12. A wind turbine comprising: a tower, a nacelle, and a rotor having a rotor hub and a plurality of rotor blades, wherein at least one rotor blade of the plurality of rotor blades is the rotor blade as claimed in claim 11.

13. A method comprising: producing a fiber-reinforced composite blank for producing a fiber-reinforced composite component of a wind turbine, the producing comprising: providing a form core comprising a form core material; providing a fiber layer comprising a fiber layer material; forming a layered structure by layered arrangement of the form core and the fiber layer; providing a plurality of reinforcing rods comprising a reinforcing material, wherein the reinforcing material has a greater stiffness than the form core material; positioning the plurality of reinforcing rods, wherein the plurality of reinforcing rods are positioned at an angle to a form core plane, and at least one reinforcing rod of the plurality of reinforcing rods is positioned at an angle to a direction orthogonal to the form core plane; and introducing the plurality of reinforcing rods into the form core.

14. The method as claimed in claim 13, wherein the reinforcing rods are introduced into the form core at a pressure of between 1 bar and 10 bar.

15. A method comprising: producing a fiber-reinforced composite component for a wind turbine for a rotor blade of a wind turbine, the producing comprising: producing a fiber-reinforced composite blank as claimed in claim 1, bringing a matrix material into contact with the form core and the plurality of reinforcing rods in the form core, wherein at least portions of the plurality of reinforcing rods and the form core are embedded in the matrix material, and curing the matrix material, wherein the cured matrix material forms a composite and binds the composite to the fiber layer.

16. The method as claimed in claim 14, wherein the pressure is between 4 bar and 8 bar.

17. The fiber-reinforced composite blank as claimed in claim 4, wherein the foam is rigid foam or metal foam.

18. The fiber-reinforced composite blank as claimed in claim 3, wherein the plurality of reinforcing rods have a diameter between 2 mm and 5 mm.

19. The fiber-reinforced composite blank as claimed in claim 2, wherein the plurality of reinforcing rods extend completely or partially through the form core in a direction from a first end surface of the layered structure to a second end surface of the layered structure, wherein the first end surface lies opposite the second end surface.

20. The fiber-reinforced composite blank as claimed in claim 19, wherein the plurality of reinforcing rods extend completely or partially through the fiber layer.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0104] Preferred embodiment examples are explained by way of example with reference to the accompanying figures, of which:

[0105] FIG. 1 shows a schematic three-dimensional view of one illustrative embodiment of a wind turbine;

[0106] FIG. 2 shows a schematic three-dimensional illustration of a fiber-reinforced composite blank according to one embodiment example;

[0107] FIG. 3 shows a schematic three-dimensional illustration of a fiber-reinforced composite component according to one embodiment example;

[0108] FIG. 4 shows a schematic three-dimensional illustration of a fiber-reinforced composite blank according to one embodiment example;

[0109] FIG. 5 shows a schematic three-dimensional sectional illustration of a rotor blade according to one embodiment example;

[0110] FIG. 6 shows a schematic two-dimensional illustration of a rotor blade according to one embodiment example;

[0111] FIG. 7 shows illustrative method steps for the production of a fiber-reinforced composite blank according to one embodiment example; and

[0112] FIG. 8 shows illustrative method steps for the production of a fiber-reinforced composite component according to one embodiment example.

[0113] In the figures, identical or substantially functionally identical or similar elements are designated with the same reference signs.

DETAILED DESCRIPTION

[0114] FIG. 1 shows a schematic three-dimensional view of one illustrative embodiment of a wind turbine. The wind turbine 100 has a tower 102 and a nacelle 104 on the tower 102. An aerodynamic rotor 106 with three rotor blades 108 and a spinner 110 is provided on the nacelle 104. The aerodynamic rotor 106 is set in rotation by the wind during operation of the wind turbine, and thus also rotates an electrodynamic rotor or runner of a generator, which is directly or indirectly coupled to the aerodynamic rotor 106. The electric generator is arranged in the nacelle 104 and generates electric energy. Fiber-reinforced composite components 200 can be used for different components of the wind turbine 100. According to this illustrative embodiment, a rotor blade 108 comprises a rotor blade element 1080 having at least one fiber-reinforced composite component 200 as described herein.

[0115] FIG. 2 shows a schematic, three-dimensional view of a fiber-reinforced composite blank 210. The fiber-reinforced composite blank 210 comprises a layered structure having a top fiber layer 230b, a form core 220 and a bottom fiber layer 230b. For better illustration, a form core material of the form core 220 and a fiber layer material of the top fiber layer 230a and of the bottom fiber layer 230b are illustrated as transparent in FIG. 2. In this case, the form core 220 spaces apart the top fiber layer 230a and the bottom fiber layer 230b. Moreover, the fiber-reinforced composite blank 210 comprises a plurality of reinforcing rods 240, which are introduced into the form core 220 at an angle greater than 0° to a form core plane 2210 and at an angle unequal to 90° to the form core plane 2210. According to this illustrative embodiment, the reinforcing rods 240 extend through the top fiber layer 230a, the form core 220 and the bottom fiber layer 230b. It is thereby possible to bind the fiber layers 230a, 230b to the form core 220 and, in particular, to improve transfer of shear forces between the fiber layers 230a, 230b and preferably between one of the fiber layers 20a, 230b and the form core 220.

[0116] FIG. 3 shows a fiber-reinforced composite component 200 having a top fiber layer 230b, a form core 220, a bottom fiber layer 230b and a plurality of reinforcing rods in a schematic, three-dimensional view. In this case, the form core 220 has a sheet-like extent in a form core plane 2210, and an extent in the thickness direction defined by the thickness 2220, which extends orthogonally to the form core plane. In this case, the form core plane 2210 is generated substantially by a longitudinal axis and a transverse axis of the form core. In this case, the particular preference is that the longitudinal axis and the transverse axis intersect at a central point and/or a center of gravity of the fiber-reinforced composite component 200.

[0117] According to this embodiment, an end surface of the layered structure defined by a surface of the top fiber layer 320a has a plurality of locations of introduction 310a-310e. Here, the locations of introduction 310a-310e define a plurality of regions of introduction 320a-320e, which are spaced apart from one another. First regions of introduction 320a-320c are substantially in the form of a line and each comprise three locations of introduction 310a-310c. In this embodiment, second regions of introduction 320d, 320e are provided, these being defined by locations of introduction 310d, 320e. These regions of introduction 320d, 320e comprise four locations of introduction 310e or five locations of introduction 310d, which are arranged substantially in a ring shape. According to this embodiment example, the fiber-reinforced composite component 200 has regions that have more reinforcing rods 3300 and regions that have fewer reinforcing rods 3400.

[0118] The fiber-reinforced composite component 200 comprises a cured matrix material, which embeds the reinforcing rods into the form core 220 and into the fiber layers 230a, 230b. In this case, the matrix material binds a composite consisting of the form core 220 and reinforcing rods to the fiber layers 230a, 230b. In addition, the matrix material seals the locations of introduction 310a-310e. It is thereby possible, in particular, to prevent failure due to bearing stress.

[0119] FIG. 4 shows a schematic illustration of a fiber-reinforced composite blank 210 in a three-dimensional view. The fiber-reinforced composite blank 210 has a top fiber layer 230a, a form core 220 and a bottom fiber layer 230b. For better illustration, a form core material of the form core 220 and a fiber layer material of the top fiber layer 230a and of the bottom fiber layer 230b are illustrated as transparent in FIG. 4. Here, the form core 220 acts as a spacer and spaces the top fiber layer 230a apart from the bottom fiber layer 230b. The upper end surface of the layered structure comprising the fiber layers 230a, 230b and the form core 220, which is defined by a surface of the top fiber layer 230a, has five locations of introduction 310, which define a substantially annular region of introduction 320. The locations of introduction 310 are spaced apart from one another in a substantially uniform manner. Starting from the locations of introduction, the reinforcing rods 240 extend through the top fiber layer 230a into the form core 220. In this case, a maximum diameter of the region of introduction 320 is extended over the thickness of the form core 220. Here, the reinforcing rods 240 essentially define a truncated cone.

[0120] FIG. 5 shows a schematic three-dimensional view of a sectional illustration of a rotor blade 108. The rotor blade 108 has a rotor blade element 1080 comprising a fiber-reinforced composite component 200. Here, the fiber-reinforced composite component 200 has a plurality of reinforcing rods 240, which reinforce the fiber-reinforced composite component 200 and consequently also the rotor blade element 1080 or rotor blade 108.

[0121] In corresponding fashion, FIG. 6 shows a rotor blade 108 in a schematic, two-dimensional view comprising a rotor blade element 1080, which comprises a fiber-reinforced composite component 200.

[0122] FIG. 7 shows a method for producing a fiber-reinforced composite blank for the production of a fiber-reinforced composite component. In this case, the individual constituent parts of the fiber-reinforced composite blank, comprising a form core 710 and two fiber layers 720, 730, are first of all made available. In a subsequent step 740, these constituent parts are arranged in layers in the sequence fiber layer—form core—fiber layer, with the result that a first fiber layer forms a bottom fiber layer, a second fiber layer forms a top fiber layer, and the fiber layers are spaced apart by the form core. Furthermore, a continuous reinforcing material, which is wound onto a coil, is made available 750 and cut 751 to a defined length using a hand tool. Continuous reinforcing material cut in this way defines a reinforcing rod and is introduced 760 into the layered structure comprising the form core and the two fiber layers. In this process, the reinforcing rod, in particular an air pistol for shooting in the reinforcing rod, is first of all positioned 761 at an angle of less than 90° and greater than 0° to the form core plane. Following this, the reinforcing rod is shot 762 through the top fiber layer into the form core by means of the air pistol. The steps of cutting 751 the continuous reinforcing material to a defined length, of positioning 761 the reinforcing rod cut in this way, and of shooting 762 the reinforcing rod through the top fiber layer into the form core are repeated multiple times. In this process, the continuous reinforcing material is cut to different lengths and shot into the layered structure at different angles.

[0123] FIG. 8 shows individual method steps 810-890 of a method for producing a fiber-reinforced composite component. In this case, a fiber-reinforced composite blank 810-862 is first of all produced. During this process, a form core 810 and a fiber layer 820 are first of all made available. In a subsequent step, these constituent parts are arranged in layers in the sequence fiber layer 820—form core 810, with the result that the fiber layer forms a bottom fiber layer and the form core adjoins the fiber layer. In addition, reinforcing rods are made available 850. The reinforcing rods are introduced 860 individually into the form core by means of an air pistol. In this process, an air pistol with a reinforcing rod is first of all positioned 861 on the form core at an angle of less than 90° and greater than 0° to the form core plane. Following this, the reinforcing rod is shot 862 into the form core by means of the air pistol, with the result that it extends through the form core. Furthermore, a fiber layer is made available 830 and arranged 870 as a layer on the form core, with the result that it forms a top fiber layer and is spaced apart from the bottom fiber layer by the form core. In a subsequent step, the layered structure is provided 880 with a film, and the layered structure surrounded by the film is evacuated 881 by means of a vacuum pump. A temperature-controlled, liquid matrix material is thereby sucked 882 into the layered structure, i.e., into the form core and into the fiber layers. In this step, the fiber layer material of the fiber layers and the form core material of the form core are impregnated with the matrix material. Finally, the matrix material is cured 890. The cured matrix material embeds the reinforcing rods introduced into the form core and binds the individual constituent parts, i.e., the fiber layers, the form core and the reinforcing rods, to one another.

[0124] Fiber-reinforced composite components or fiber-reinforced composite blanks, comprising a fiber layer 230a, 230b, a form core 220, and reinforcing rods 240 introduced into the form core 220 have various advantages. In particular, a shear stiffness and a bending stiffness of the fiber-reinforced composite component 200 can be increased by introducing reinforcing rods 240 at different angles. Moreover, it is possible, in particular, to adapt a property of the fiber-reinforced composite component 200 to local loads in order thereby to permit optimum material utilization in terms of lightweight construction.

LIST OF REFERENCE SIGNS

[0125] 100 wind turbine

[0126] 102 tower

[0127] 104 nacelle

[0128] 106 aerodynamic rotor

[0129] 108 rotor blade

[0130] 110 spinner

[0131] 200 fiber-reinforced composite component

[0132] 210 fiber-reinforced composite blank

[0133] 220 form core

[0134] 230a, 230b fiber layer; top fiber layer, bottom fiber layer

[0135] 240 reinforcing rod

[0136] 310, 310a-310e location of introduction

[0137] 320, 320a-320e region of introduction

[0138] 710 making available a form core

[0139] 720 making available a fiber layer, bottom side

[0140] 730 making available a fiber layer, top side

[0141] 740 arranging in layers

[0142] 750 making available a continuous reinforcing material

[0143] 751 cutting the continuous reinforcing material to a defined length (reinforcing rod)

[0144] 760 introducing the reinforcing rods

[0145] 761 positioning the reinforcing rod or air pistol

[0146] 762 shooting in the reinforcing rod

[0147] 810 making available a form core

[0148] 820 making available a fiber layer, bottom side

[0149] 830 making available a fiber layer, top side

[0150] 840 arrangement in layers

[0151] 850 making available reinforcing rods

[0152] 860 introducing the reinforcing rods

[0153] 861 positioning the reinforcing rod

[0154] 862 shooting in the reinforcing rod

[0155] 870 arrangement in layers

[0156] 880 providing the layered structure with a film

[0157] 881 evacuating the layered structure

[0158] 882 sucking the matrix material into the layered structure

[0159] 890 curing the matrix material

[0160] 1080 rotor blade element

[0161] 2210 form core plane

[0162] 2220 thickness

[0163] 3300 region having more reinforcing rods

[0164] 3400 region having fewer reinforcing rods