Method of Manufacture and the Resulting Vertical Axis Wind Turbine Airfoil

Abstract

A Method of Manufacture for a Vertical Axis Wind Turbine Airfoil by injecting high-density foam into a light-weight air-foil framed-structure assembled by predefined snap-together glue-less components. For alignment, and proper inner frame component positioning the assembly of the framed-structure components is assisted by a table holding in place the frame's forward and aft spar. The internal cross member rib locking-supports have circular-dove-tail-locking snap-together ends. A plurality of the internal light-weight wooden component members is laminated with 0.020 to 0.040 aluminum. The assembled frame structure is placed between non-stick sheets within a custom mold which is then clamped down upon the framed structure and injected with high-density foam. The high-density injected frame structure is then carbon fiber resin infused in a vacuum bagged processed.

Claims

1. A Method of Manufacture for a Vertical Axis Wind Turbine Airfoil, comprising the steps of: Step 1 is to laminated Baltic Birch 5-layer plywood (number 33) with 0.040 aluminum on the top and bottom side. Step 2 the Vertical Axis Wind Turbine Airfoil Internal Component Foil Structure pieces are cut out of the said 0.040 laminated Baltic Birch 5-layer plywood (number 31). Step 3 Align and slide the laminated ribs (number 1) on the two identical Alignment Laminated Support Struts (number 4) sliding into the Forward Laminated Support Rib Holes (number 11), and Trailing Laminated Support Rib Holes (number 18). Step 4. The unit consisting of the assembled Laminated Ribs and Alignment Laminated Support Struts from Step 3 will be placed in a horizontal and parallel position to the Assembly Alignment Table (number 44) and the Alignment Laminated Support Struts of the said assembled unit will attached or lay upon the Attachment Member (number 45) of the Assembly Alignment Table (number 44). Step 5. The Leading-Edge Strut (number 2) is snapped by pressure fitted into the plurality the Leading-Edge Rib Notches (number 10) on each of the Laminated Ribs (number 1). Step 6. The Vertical Struct Notches (number 22) of the Vertical Struts (number 3) are snapped by pressure fitness into place within the Laminated Rib Notches (number 15). Step 7. The Trailing-Edge Laminated Support Struts (number 7) are then snapped into the Trailing-Edge Rib Notches (number 21). Step 8. The Leading-Edge Laminated Support Struts (number 2) are then snapped into the Leading-Edge Rib Notches (number 10). Step 9. The plurality of Circular Dove Tail Male Connectors (number 17) of the plurality of strut locks (numbers 5, 23,24,25, and 26) are snapped into Vertical Strut Female Connector (number 16) of the Vertical Struts (number 3). Step 10. The assembly of Step 9 is placed onto a Bottom Protective Teflon Sheet (number 37) which is all set on top of the Base Mold Form (number 36). The Base Mold Form (number 36) is setup and attached by the Aluminum External Mold Supports (number 40) to Mold Support Table (number 35). Step 11. A Top Protective Teflon Sheet (number 38) is now placed upon the top of the assembled components in Step 10. Step 12. The Top Mold Form (number 39) is now closed using Hinge (number 43) and is latched and Mold Latching Member (number 41) upon the top of the assembled components from Step 11. Step 13. High density internal wing foam (number 8) is injected into the cavities of the internal component parts within the mold. Step 14. Upon the foam curing then completely assembled internal components which are now one bonded unit of fold are remove from the mold and the Teflon sheet is peeled away from the air foil. Step 15 Air foil is lastly covered with a top coat of carbon fiber.

2. The resulting Vertical Axis Wind Turbine Airfoil produced from the Method of Manufacture for a Vertical Axis Wind Turbine Airfoil as in claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWING FIGURES

[0034] FIG. 1 is an illustrative view of the cut-away of the top of the assembled Vertical Axis Wind Turbine Airfoil components.

[0035] FIG. 2 is an illustrative view of the interconnection of the laminated ribs, vertical struts, and vertical strut locks.

[0036] FIG. 3 is an illustrative view of the of vertical strut locks.

[0037] FIG. 4 is an illustrative view of the double-T locking mechanized of the Alignment Laminated Support Strut and the Double Tee Struct Splice

[0038] FIG. 5 is an illustrative view of interconnection of the Baltic Birch 5-layer plywood, Top Aluminum Lamination, and the Baltic Birch 5-layer plywood.

[0039] FIG. 6 is an illustrative view of the Mold support table, Base Mold Form, and associated components.

[0040] FIG. 7 is an illustrative view of the Assembly Alignment Table.

DESCRIPTION OF THE REFERENCED NUMBERS

[0041] Turning now descriptively to the drawings, in which similar reference in characters denote the similar elements throughout the several views, the figures illustrate a method of manufacture for a vertical axis wind turbine airfoil and the resulting vertical axis wind turbine airfoil. With regard to the reference numerals used, the following numbering is used throughout the various drawing's figures: [0042] 1. Laminated Rib [0043] 2. Leading-Edge Laminated Support Strut [0044] 3. Vertical strut [0045] 4. Alignment Laminated Support Strut [0046] 5. Position four vertical strut lock [0047] 6. Double Tee Struct Splice [0048] 7. Trailing-Edge Laminated Support Strut [0049] 8. High density internal wing foam [0050] 9. External layer of carbon fiber [0051] 10. Leading-Edge Rib Notch [0052] 11. Forward Laminated Support Rib Hole [0053] 12. Forward Laminated Rib cutaway [0054] 13. Forward Laminated Rib cutaway [0055] 14. Aft Laminated Rib cutaway [0056] 15. Laminated Rib notchto receive vertical strut [0057] 16. Vertical Strut Female Connector [0058] 17. Circular Dove Tail Male Connector [0059] 18. Trailing Laminated support Rib Hole [0060] 19. Middle high-density expanding foam portal entry [0061] 20. Trailing high-density expanding foam portal entry [0062] 21. Trailing-Edge Rib Notch [0063] 22. Vertical strut notch 23 Position one vertical strut lock [0064] 24. Position two vertical strut lock [0065] 25. Position three vertical strut lock [0066] 26. Position five vertical strut lock [0067] 27. Steel tubing [0068] 28. High density expanding foam [0069] 29. Vertical Interlocking laminated Baltic Birch interior laminate [0070] 30. Horizontal Interlocking laminated Baltic Birch interior laminate [0071] 31. Baltic Birch 5-layer plywood Laminated [0072] 32. Top Aluminum Lamination [0073] 33. Baltic Birch 5-layer plywood [0074] 34. Bottom Aluminum Lamination [0075] 35. Mold support table [0076] 36. Base Mold Form [0077] 37. Bottom Protective Teflon Sheet [0078] 38. Top Protective Teflon Sheet [0079] 39. Top Mold Form [0080] 40. Aluminum External Mold Support [0081] 41. Mold Latching Member [0082] 42. Locking assembly screw [0083] 43. Mold Rear Hinge [0084] 44. Assembly Alignment Table [0085] 45. Attachment Member of the Assembly Alignment Table

Definitions

[0086] 1. The term circular-dove-tail-locking as used herein, refers to a pressure fit locking together mechanism in which a circular protruding member fits tightly and snuggly into an existing cutout.
2. The term pressure fit locking together mechanism as used herein, refers to pressure tight enough to join the lock without needing any other assistance like for example glue.
3. The term light-weight air-foil as used herein refers to an air foil that is generally lighter in weight than other air foils on the market and in which the inventor's air foil is using thin 5 ply Baltic Birch laminated on both sides with 0.020 inch to 0.040-inch aluminum.
4. The term laminated rib as used herein refers to the 5 ply Baltic Birch wood laminated with from 0.020 to 0.040 aluminum component member. These are internal components providing structural support and attachment points for other component pieces of the overall frame of the air foil.
5. The term leading-edge strut as used herein refers the component that traverses the whole front end of the wing attaching together the multiple ribs of the Air Foil. This leading-edge strut attaches to each of the front notched groove on each multiple rib. The front notched groove on each multiple rib is illustrated in FIG. 2 referenced numbered element 11.
6. The term Laminated Rib cutaway as used herein refers a cut out in a laminated rib for the purpose of lightening the overall laminated rib weight and additionally allowing the impregnated foam to flow through to the other ribs within the frame.
7. The term Predetermined Vertical Axis Wind Turbine Airfoil Internal Component Foil Structure Pieces as used herein refers all of the Internal Component Frame Structure Pieces making up the Air frame consisting of Laminated Rib, Leading-edge strut, Vertical strut, Alignment Laminated Support Strut, Position four Internal locking circular dove tail support, Trailing Edge laminated Support Strut, the Internal locking circular dove tail supports.
8. The term Laminated Rib as used herein refers a plurality of internal supporting structures as shown FIG. 1 numerated number one.
9. The term Alignment Laminated Support Strut as used herein refers to the two support internal struts that slide into the Laminated Ribs. The two holes in each laminated Rib are named Forward Laminated Support Rib Hole (number 11) and the trailing laminated support rib hole.
10. The term Laminated Rib notches as used herein refers a plurality of rib notches on the edge of the Laminated Ribs.
11. The term vertical strut locks used herein refers to an internal component that locks the vertical struts (number 3) together and also assists in holding the placement of the vertical structs that were previously snapped into the laminated ribs (number 1).
12. The term Double tee Struct Splice (number 6) used herein refers a connective splice utilizing a pressure fit connection that attaches and lengthens vertical structs as needed. A Double tee Struct Splice is shown in the bottom of FIG. 4.
13. The term wing used herein refers to all of the assembled Vertical Axis Wind Turbine Airfoil components.
14. The term rib chamber sections used herein refers the gap of span between the individual parallel laminated ribs comprising the overall wing.
15. The term middle high-density expanding foam portal entry (number 19) as used herein refers a member that allows for the free flow of high-density foam between rib chamber sections.
16. The term Trailing high-density expanding foam portal entry (number 19) as used herein refers a member that allows for the free flow of high-density foam between rib chamber sections.

PREFERRED EMBODIMENT

[0087] The preferred embodiment of this invention is for use on a vertical axis wind turbine.