BLADE FOR A ROTOR OF A WIND TURBINE AND MANUFACTURING METHOD THEREOF

Abstract

An anti and/or de-icing blade and manufacturing method for said blade including a pressure side shell and a suction side shell, the shells including at least one electrical connector layer extending from the leading edge towards the trailing edge, at least one heating elements layer electrically in contact with the electrical connector layer, glass fabric layers at least inwardly in contact with the electrical connector or with heating elements layer, a connector component extending transversally through the glass fabric layers and being electrically connected with the electrical connector layer and with a metallic block which is drilled by an inter-connector so that the electrical connector layers from each shell are electrically connected and the blade is able to be heated when electrically fed from power source.

Claims

1. A blade for a rotor of a wind turbine, comprising a profiled contour formed by a pressure side shell and a suction side shell rigidly joined thereof, the blade comprising a blade root, a blade tip, a leading edge and a trailing edge with a chord extending therebetween, the pressure side shell and the suction side shell comprising: at least one electrical connector layer located at a first distance from the blade root and extending from the leading edge towards the trailing edge; at least one heating elements layer electrically in contact with the electrical connector layer, the at least one heating element layer extending in a longitudinal direction therebetween the blade root and the blade tip and more proximate to the leading edge than to the trailing edge; glass fabric layers at least inwardly in contact with the electrical connector or with the at least one heating elements layer; a connector component extending transversally through the glass fabric layers and being electrically connected with the electrical connector layer and with a metallic block; and power wires extending longitudinally from a power source near the blade root to the connector component being one of the power wires electrically in contact thereof, the power wires located in at least one of the suction side shell and the pressure side shell wherein the metallic block is drilled by an inter-connector so that the electrical connector layers from the suction side shell and the pressure side shell are electrically connected and the blade is able to be heated by the at least one heating elements layer when electrically fed from the power source.

2. The wind turbine blade of claim 1, wherein each of the suction side shell and the pressure side shell further comprises second glass fabric layers outwardly in contact with the at least one heating elements layer or the electrical connector layer.

3. The wind turbine blade of claim 1, wherein the at least one heating elements layer is outwardly in contact with the electrical connector layer.

4. The wind turbine blade of claim 1, wherein the at least one heating elements layer is inwardly in contact with the electrical connector layer.

5. The wind turbine blade of claim 4, comprising a second electrical connector layer electrically and outwardly in contact with the electrical connector layer and alternatively also being electrically in contact with the connector component.

6. The wind turbine blade of claim 1, wherein each of the suction side shell and the pressure side shell further comprises a second heating element layer electrically and outwardly in contact with the electrical connector layer, the second heating element layer extending therebetween the leading edge and the trailing edge and adjacently to the at least one heating element layer.

7. The wind turbine blade of claim 1, wherein each of the suction side shell and the pressure side shell comprises a plurality of electrical connector layers extending between the blade root and the blade tip beyond distance, wherein each electrical connector layer is electrically connected to a corresponding heating element layer and a connector component which in turn is electrically connected to a metallic block and one of the power wires, so that another region of the blade can be heated independently with different heating elements.

8. The wind turbine blade of claim 1, wherein a heating element is a carbon fibre with a biaxial structure, ±45° respect to the blade longitudinal direction, carbon veil or any composite fabric including conductive components.

9. The wind turbine blade of claim 1, wherein the electrical connector is a copper or aluminum mesh, or any composite materials with metallic additives or wires.

10. The wind turbine blade of claim 1, wherein the electrical connector is 20-400 mm wide and 50-500 μm of thickness.

11. A method for manufacturing the blade of claim 1, wherein during manufacturing of each of the suction side shell and the pressure side shell the method comprising: placing one electrical connector layer on a mould with the contour profile of the corresponding shell and connect the electrical connector layer to the connector component thereof; and applying glass fabrics layers in a way that the glass fabrics layers are placed inwardly or outwardly in contact with respect to the electrical connector layer, so that if outwardly in contact the glass fabrics layers are placed in the mould before the electrical connector layer, and if inwardly in contact the glass fabrics layer are placed in the mould after the electrical connector layer.

12. The method for manufacturing of claim 11, comprising the step of installing and/or connecting the metallic block and the power wires to the connector component during or after the manufacturing of each shell.

13. The method for manufacturing of claim 11, comprising the step of applying the at least one heating element layer electrically in contact outwardly or inwardly to the electrical connector layer, during the manufacturing of each of the suction side shell and the pressure side shell and before shell infusion and curing.

14. The method for manufacturing according to claim 11, further comprising the step of applying a plastic adhesive tape in a region on the leading edge during the manufacturing of each of the suction side shell and the pressure side shell and before demoulding, and after the suction side shell and the pressure side shell have been rigidly joined together apply the at least one heating elements layer on the region where the plastic adhesive tape was originally placed.

15. The method for manufacturing according to any claim 11, wherein after the suction side shell and the pressure side shell have been rigidly joined, the metallic blocks are drilled with the inter-connector.

Description

BRIEF DESCRIPTION

[0039] Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members, wherein:

[0040] FIG. 1 depicts a front view of an exemplary embodiment of the blade where it can be seen the heating elements layers extending therebetween the blade root and the blade tip;

[0041] FIG. 2 depicts a partial view of FIG. 1 illustrating a first cross section at A-A′ and a second cross section B-B′;

[0042] FIG. 3 depicts a detailed view of a first embodiment of a cross section A-A′;

[0043] FIG. 4 depicts a detailed view of a second embodiment of a cross section A-A′;

[0044] FIG. 5 depicts a detailed view of a first embodiment of the cross section B-B′ represented at FIG. 3;

[0045] FIG. 6 depicts a detailed view of a second embodiment of the cross section B-B′ of FIG. 4;

[0046] FIG. 7A depicts a cross-sectional side view of an embodiment at section A-A′, clearly showing the metallic blocks (11) drilled by an inter-connector (12);

[0047] FIG. 7B depicts a detailed view of a third embodiment of cross section A-A′;

[0048] FIG. 8A depicts a cross-sectional side view of a third embodiment at section A-A′ of FIG. 7B;

[0049] FIG. 8B depicts a detailed view of a fourth embodiment of a cross section A-A′; and

[0050] FIG. 9 depicts a detailed view of a fifth embodiment of the cross section A-A′.

DETAILED DESCRIPTION

[0051] What follows is a detailed description, with the help of the attached FIGS. 1-9 referenced above, of an exemplary embodiments of the aspect of the present invention.

[0052] The embodiment of the present invention relates to a blade and method of manufacturing of said blade for de-icing or anti-icing purposes.

[0053] Firstly, the blade of the present invention is explained below.

[0054] In a first aspect of the embodiment of the present invention it is described a blade which can be generally applied to any blade for a wind turbine rotor that involves heating with one or more heating elements.

[0055] More in a particular, the blade may comprise, see FIG. 1, a profiled contour formed by a pressure side shell (7) and a suction side shell (8) rigidly joined thereof, further comprising a blade root (1), a blade tip (2), a leading edge (3) and a trailing edge (4) with a chord extending therebetween.

[0056] Moreover, each shell may comprise at least one electrical connector layer (5) located at a first distance L1 from the blade root (1) and extending from the leading edge (3) towards the trailing edge (4), at least one heating elements layer (6) electrically in contact with the electrical connector layer (5), wherein said heating element layer (6) extending in a longitudinal direction therebetween the blade root (1) and the blade tip (2) and more proximate to the leading edge (3) than to the trailing edge (4).

[0057] Additionally, in several embodiments glass fabric layers (9) are inwardly in contact with the electrical connector layer (5) or with heating elements layer (6)—depending on the arrangement between said layers (5,6) which may be inwardly or alternatively outwardly in contact thereof—and the blade further comprises a connector component (10) extending transversally through the glass fabric layers (9) and being electrically connected with the electrical connector layer (5) and with a metallic block (11).

[0058] the blade may further comprise power wires (13) extending longitudinally from a power source near the blade root (1) to the connector component (10) being electrically in contact thereof, said power wires (13) located in at least one of the shells (7,8), and wherein the aforementioned metallic blocks (11) are drilled by an inter-connector (12) so that the electrical connector components (10) from each shell (7,8) are electrically connected and the blade is able to be heated by the heating elements layer (9) when electrically fed from the power source

[0059] It should be appreciated that the aforementioned blade may comprise several embodiments with different combination regarding the respective order of the plurality of aforementioned layers.

[0060] Additionally, the heating elements layer (6) may be applied during the manufacturing and before infusion and curing or after the pressure shell (7) and the suction shell (8) have been rigidly joined.

[0061] In FIG. 1, it is shown as example, a blade comprising three heating elements (6) on one shell. The first having electrical connectors (5a, 5b), for the second being (5c, 5d) and for the third (5e, 5f). One of each electrical connectors for each heating element (6) connected to one power wire (13).

[0062] FIG. 2, shows a partial view of the blade of FIG. 1, showing two cross sections, a first cross section A-A′ and a second cross section B-B′. The two electrical connectors (5a, 5b) for heating element (6) shall be connected to two different power wires (13) in order to be fed from a power source.

[0063] Referring now to FIG. 3, in a first embodiment each shell (7,8) further comprises second glass fabric layers (9) outwardly in contact with the heating elements layer (6) or the electrical connector layer (5).

[0064] Moreover, as can be appreciated in FIG. 3 the heating elements layer (6) is outwardly in contact with the electrical connector layer (5) during the manufacturing of the blade at cross section A-A′. In another embodiment the heating element layer (6) may be inwardly in contact with the electrical connector layer (5).

[0065] Referring now to FIG. 4, in a second exemplary embodiment it is shown that the farthest and exterior layer is the heating elements layer (6) in electrical contact with adjacent electrical connector layer (5) inwardly displaced therein.

[0066] FIG. 5 illustrates the second section B-B′ of the blade according to the aforementioned first embodiment. It can be clearly appreciated that the electrical connector layer (5) does not extend along all the longitudinal direction of the blade but rather at the connections at the heating elements layer (6) ends, one of them clearly being section A-A′ in FIG. 3. Thus, it is not shown at FIG. 5.

[0067] As can be appreciated in FIG. 5, section B-B′ comprises glass fabric layers inwardly and outwardly of the heating element layer (6).

[0068] Referring now to FIG. 6 it illustrates second section B-B′ of the blade according to the aforementioned second embodiment. It can be clearly appreciated that the electrical connector layer (5) does not extend along all the longitudinal direction of the blade but rather at the connections at the heating elements layer (6) ends, one of them clearly being section A-A′ in FIG. 6.

[0069] As can be appreciated in FIG. 6, section B-B′ comprises glass fabric layers inwardly of the heating element layer (6) farthest exteriorly—closer to the molds (15).

[0070] Referring now to FIG. 7A it is therein illustrated a cross-sectional side view at section A-A′, where it is clearly shown the aforementioned metallic blocks (11) are drilled by an inter-connector (12) so that the electrical connector layer (10) from each shell (7,8) are electrically connected and the blade is able to be heated by the heating elements layer (9) when electrically fed from the power source.

[0071] Referring now to FIG. 7B and FIG. 8A, it is therein exemplified a third exemplary embodiment wherein the heating element layer (6) its not applied during the manufacturing of each shell (7,8). Rather a plastic adhesive tape (14) is applied farthest towards the exterior, and the heating elements layer (6) is applied after the shells (7,8) have been rigidly joined—see FIG. 8A—. In this FIG. 8A, it is not represented the electrical connection layer (10), which may be electrically connecting the electrical connector layer (5) with the metallic block (11).

[0072] FIG. 8B illustrates a fourth embodiment wherein a first heating elements layer (6) is applied during manufacturing extending therebetween the leading edge (3) and the trailing edge (4).

[0073] Moreover, in the fourth embodiment it may be applied a plastic adhesive tape (14) in the leading edge which may be not in contact with the first heating elements (6) and after the shells (7,8) have been rigidly joined the plastic adhesive tape (14) may be removed and second heating elements layer (6) may be applied therein in the leading edge (3) in electric contact with the electric connector layer (5).

[0074] Referring to FIG. 9 in a yet further embodiment each shell (7,8) may comprise two electrical connector layers (5) wherein the heating elements layer (6) may be in electrical contact with each electrical connector layers (5) and located therebetween.

[0075] In an exemplary embodiment the heating element of the heating elements layer (6) may be carbon fiber with a biaxial structure, ±45° respect to the blade longitudinal direction, or carbon veil.

[0076] Furthermore, in a further exemplary embodiment the electrical connector layer (5) comprises a copper or aluminum mesh, or any composite materials with metallic additives or wires.

[0077] Said electrical connectors may be 20-400 mm wide and 50-500 μm of thickness.

[0078] In an exemplary embodiment each shell (7,8) comprises a plurality of electrical connector layers (5a-5f) extending between the blade root (1) and the blade tip (2) beyond distance L1, wherein each electrical connector layer (5a-5f) is electrically connected to a corresponding heating element layer (6) and to a connector component (10) which in turn is electrically connected to a metallic block (11) and power wires (13), so that another region of the blade can be heated independently with different heating elements—see FIG. 1—.

[0079] In other words, cross section, A-A′ of any of the several embodiments can be reproduced a plurality of times along the blade longitudinal direction at every end of the heating elements layer (6).

[0080] In a second aspect of the present invention it is described a method for manufacturing the blade before described in any of the embodiments, wherein during the manufacturing of each shell (7,8) and before demolding the method comprises, at least: [0081] a) placing one electrical connector layer (5) on a mold with the contour profile of the corresponding shell (7,8) and connect said electrical connector layer (5) to the connector component (10) thereof, [0082] b) applying glass fabrics layers (9) in a way they are placed inwardly or outwardly in contact with respect to said electrical connector layer (5), so that if outwardly in contact they are placed in the mold before the electrical connector layer (5), and if inwardly in contact they are placed in the mold after the electrical connector layer (5).

[0083] In an exemplary embodiment the method further comprises the step of connecting the metallic block (11) and the power wires (13) to the connector component (10) before or after the infusion and curing of each shell (7,8).

[0084] Moreover, in an exemplary embodiment the method further comprises the step of applying a heating element layer (6) electrically in contact outwardly or inwardly to the electrical connector layer (5), during the manufacturing of each shell (7,8) and before their infusion and curing.

[0085] In another embodiment, the method comprises the step of applying a plastic adhesive tape (14) in a region on the leading edge (3) during the manufacturing of each shell (7,8) and before demolding, and after the shells (7,8) have been rigidly joined together apply a heating elements layer (6) on the region where the plastic adhesive tape (14) was originally placed.

[0086] Finally, after the shells (7,8) have been rigidly joined, the metallic blocks (13) may be drilled with the inter-connector (12) so that the electrical connector layers (10) from each shell (7,8) are electrically connected and the blade is able to be heated by the heating elements layer (6) when electrically fed from the power source.

[0087] Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.

[0088] For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements.