REINFORCING STRUCTURE FOR A WIND TURBINE BLADE
20230016436 · 2023-01-19
Inventors
- Klavs Jespersen (Kolding, DK)
- Rama RAZEGHI (Eastleigh Hampshire, GB)
- Dylan REDMOND-GRAY (Eastleigh Hampshire, GB)
Cpc classification
B32B3/266
PERFORMING OPERATIONS; TRANSPORTING
F05B2240/301
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02P70/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F03D1/0675
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C70/882
PERFORMING OPERATIONS; TRANSPORTING
F05B2280/6003
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B32B5/26
PERFORMING OPERATIONS; TRANSPORTING
Y02E10/72
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B29C70/546
PERFORMING OPERATIONS; TRANSPORTING
F05B2280/2006
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B32B2262/106
PERFORMING OPERATIONS; TRANSPORTING
B32B2260/021
PERFORMING OPERATIONS; TRANSPORTING
B29C70/443
PERFORMING OPERATIONS; TRANSPORTING
B32B2603/00
PERFORMING OPERATIONS; TRANSPORTING
International classification
F03D1/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C70/34
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present invention relates to a reinforcing structure, such as a reinforcing structure for reinforcing a wind turbine blade, comprising: a first composite element layer comprising at least two carbon fibre reinforced composite elements; a second composite element layer comprising one or more carbon fibre reinforced composite elements; an interlayer sandwiched at least partly between the first and the second composite element layer, the interlayer comprising an electrically conductive portion and a non-conductive portion surrounding the conductive portion, the conductive portion abutting exactly two of the carbon fibre reinforced composite elements comprised in the first composite element layer. A method for manufacturing such a structure is also provided.
Claims
1. A reinforcing structure (300), such as for reinforcing a wind turbine blade (10), comprising: a first composite element layer comprising at least two carbon fibre reinforced composite elements (301-304, 801-810), a second composite element layer comprising one or more carbon fibre reinforced composite elements (301-304, 801-810), an interlayer (331, 831-833) sandwiched at least partly between the first and the second composite element layer, the interlayer comprising an electrically conductive portion (311, 811-816) and a non-conductive portion (421, 821-823) surrounding the conductive portion, the conductive portion abutting exactly two of the carbon fibre reinforced composite elements comprised in the first composite element layer.
2. A reinforcing structure in accordance with claim 1, wherein the conductive portion further abuts exactly two carbon fibre reinforced composite elements comprised in the second composite element layer.
3. A reinforcing structure in accordance with claim 1, wherein the conductive portion abuts exactly two of the carbon fibre reinforced composite elements comprised in the first composite element layer and abuts exactly one carbon fibre reinforced composite element comprised in the second composite element layer.
4. A reinforcing structure in accordance with claim 1, wherein a thickness of the conductive portion is within 50-150% of a thickness of the non-conductive portion.
5. A reinforcing structure in accordance with claim 1, wherein a thickness of the conductive portion is substantially identical, such as identical, to a thickness of the non-conductive portion.
6. A reinforcing structure in accordance with claim 1, wherein the conductive portion is attached to an anchor element extending from the conductive portion and in between the two carbon fibre reinforced composite elements that are comprised in the first composite element layer and abut the conductive portion.
7. A reinforcing structure in accordance with claim 6, wherein a thickness of the anchor element is between 0.1 and 1.5 mm.
8. A reinforcing structure in accordance with claim 1, wherein the non-conductive portion is made at least partly of a polyester material, such as a polyester veil, such as a woven or non-woven polyester veil.
9. A reinforcing structure in accordance with claim 1, wherein the conductive portion is made at least partly of carbon fibres.
10. A reinforcing structure in accordance with claim 1, wherein the conductive portion comprises a woven carbon fibre material.
11. A reinforcing structure in accordance with claim 1, wherein the conductive portion comprises a carbon fibre veil.
12. A reinforcing structure in accordance with claim 1, wherein the conductive portion is stitched or stapled or glued or bonded into a corresponding hole in the non-conductive portion.
13. A reinforcing structure in accordance with claim 1, wherein the composite element layers and the interlayer have been bonded together in a liquid resin infusion and curing process.
14. A reinforcing structure in accordance with claim 1, wherein the reinforcing structure is part of a wind turbine blade main laminate or is a wind turbine blade main laminate.
15. A reinforcing structure in accordance with claim 1, wherein the reinforcing structure is part of a spar structure for a wind turbine blade or is a spar structure for a wind turbine blade.
16. A reinforcing structure in accordance with claim 1, wherein one or more of the carbon fibre reinforced composite elements is at least partly made by pultrusion.
17. A reinforcing structure in accordance with claim 1, wherein a largest dimension of the conductive portion is less than 100 mm, such as less than 50 mm, such as in the range 30-60 mm, such as in the range 30-40 mm.
18. A reinforcing structure in accordance with claim 1, wherein a largest dimension of the conductive portion is equal to or less than a width of a carbon fibre reinforced composite element abutting the conductive portion, such as equal to or less than half a width of a carbon fibre reinforced composite element abutting the conductive portion.
19. A wind turbine blade reinforced with a reinforcing structure in accordance with claim 1.
20. A method for manufacturing a reinforcing structure or a wind turbine blade in accordance with claim 19, the method comprising: arranging at least two carbon fibre reinforced composite elements (301-304, 801-810) to form a first composite element layer, providing an interlayer onto the first composite element layer (331, 831-833), the interlayer comprising an electrically conductive portion (311, 811-816) and a non-conductive portion (421, 821-823) surrounding the conductive portion, the conductive portion abutting exactly two of the carbon fibre reinforced composite elements comprised in the first composite element layer, arranging at least one carbon fibre reinforced composite element (301-304, 801-810) on the interlayer to form a second composite element layer, the first and second composite element layers sandwiching at least a part of the interlayer.
21. A method in accordance with claim 20, wherein exactly one carbon fibre reinforced composite element in the second composite element layer abuts the conductive portion.
22. A method in accordance with claim 20, wherein exactly two carbon fibre reinforced composite elements in the second composite element layer abut the conductive portion.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] The invention is explained in detail below with reference to embodiments shown in the drawings.
[0049]
[0050]
[0051]
[0052]
[0053]
[0054]
[0055]
[0056]
DETAILED DESCRIPTION OF SELECTED EMBODIMENTS
[0057]
[0058]
[0059] The airfoil region 34 (also called the profiled region) has an ideal or almost ideal blade shape with respect to generating lift, whereas the root region 30 due to structural considerations has a substantially circular or elliptical cross-section, which for instance makes it easier and safer to mount the blade 10 to the hub. The diameter (or the chord) of the root region 30 may be constant along the entire root area 30. The transition region 32 has a transitional profile gradually changing from the circular or elliptical shape of the root region 30 to the airfoil profile of the airfoil region 34. The chord length of the transition region 32 typically increases with increasing distance r from the hub. The airfoil region 34 has an airfoil profile with a chord extending between the leading edge 18 and the trailing edge 20 of the blade 10. The width of the chord decreases with increasing distance r from the hub.
[0060] A shoulder 40 of the blade 10 is defined as the position, where the blade 10 has its largest chord length. The shoulder 40 is typically provided at the boundary between the transition region 32 and the airfoil region 34.
[0061] It should be noted that the chords of different sections of the blade normally do not lie in a common plane, since the blade may be twisted and/or curved (i.e. pre-bent), thus providing the chord plane with a correspondingly twisted and/or curved course, this being most often the case in order to compensate for the local velocity of the blade being dependent on the radius from the hub.
[0062] The blade is typically made from a pressure side shell part 36 and a suction side shell part 38 that are glued to each other along bond lines at the leading edge 18 and the trailing edge of the blade 20.
[0063]
[0064] The spar cap 41 of the pressure side shell part 36 and the spar cap 45 of the suction side shell part 38 are connected via a first shear web 50 and a second shear web 55. The shear webs 50, 55 are in the shown embodiment shaped as substantially I-shaped webs. The first shear web 50 comprises a shear web body and two web foot flanges. The shear web body comprises a sandwich core material 51, such as balsawood or foamed polymer, covered by a number of skin layers 52 made of a number of fibre layers. The blade shells 36, 38 may comprise further fibre-reinforcement at the leading edge and the trailing edge. Typically, the shell parts 36, 38 are bonded to each other via glue flanges.
[0065]
[0066] The carbon fibre reinforced composite elements 301-304 may for instance be pultruded elements, such as planks, that are stacked to form a reinforcing structure. Stackable shapes are typically used, as they are easier to handle when laying up the reinforcing structure. However, other shapes may be used.
[0067] A conductive portion 311 made for instance of a carbon fibre material may, as discussed previously, impede the flow of liquid resin during an infusion process meant to bond all the carbon fibre reinforced composite elements and the interlayer together to form a reinforcing structure. Thus, the size of the conducting portion is such that it provides sufficient conductance between the carbon fibre reinforced composite elements 301-304, while not significantly impeding the flow of liquid resin during an infusion process.
[0068]
[0069] The conductive portion 311 is thus embedded into the non-conductive portion 421, which may for instance be a polyester material. A polyester veil allows liquid resin to relatively easily flow between the composite element layers. As described above, the conductive portion 311 may somewhat impede flow of liquid resin, but because it extends over a relatively small area, it does not significantly affect the process of infusing liquid resin in between the carbon fibre reinforced composite elements.
[0070]
[0071] The conductive portion 311 abuts all four carbon fibre reinforced composite elements 301-304, thereby allowing lightning current to flow between all the carbon fibre reinforced composite elements, as illustrated by the dashed lines in
[0072] For simplicity and generality, the figures do not show any resin between the carbon fibre reinforced composite elements. It is to be understood that the structure will be reinforcing once resin has been infused to bond the elements together. However, this step may take place before the reinforcing structure is applied to the part to be reinforced, or the infusion may only take place as a step that at the same time forms the part to be reinforced, bonding the carbon fibre reinforced composite elements together and bonding the carbon fibre reinforced composite elements to the part to be reinforced.
[0073]
[0074]
[0075] As in
[0076]
[0077] The first composite element layer is separated from the second composite element layer by interlayer 831. The second composite element layer is separated from the third composite element layer by interlayer 832. The third composite element layer is separated from the fourth composite element layer by interlayer 833.
[0078] Interlayer 831 comprises a non-conductive portion 821 and conductive portions 811-813. Similarly, interlayer 832 comprises a non-conductive portion 822 and conductive portions 814-815. Interlayer 833 comprises a non-conductive portion 823 and a conductive portion 816. Widths W.sub.1 and W.sub.2 represent the width of the first and the second composite element layer, respectively, and will be referred to in the description of
[0079] The conductive portion 811, as an example, electrically connects carbon fibre reinforced composite elements 803 and 804 of the first composite element layer and carbon fibre reinforced composite element 807 of the second composite element layer. Similarly, conductive portion 814 electrically connects carbon fibre reinforced composite elements 806 and 807 of the second composite element layer and carbon fibre reinforced composite elements 808 and 809 of the third composite element layer. Conductive portion 816 electrically connects carbon fibre reinforced composite elements 808 and 809 of the third composite element layer and carbon fibre reinforced composite element 810 of the fourth composite element layer. As a result, lightning current can be conducted without flashover from element 804 to element 810 via conductive portions 811, 814 and 816, and via carbon fibre reinforced composite elements 807 and 809, as illustrated by the dashed line. In fact, in the embodiment in
[0080] In the exemplary embodiment 800, each conductive portion is attached to a respective anchor element, such as anchor element 861, which assists in maintaining conductive portion 815 aligned with carbon fibre reinforced composite elements 805 and 806, ensuring a high conductance between the two carbon fibre reinforced composite elements as well as carbon fibre reinforced composite element 808. In a more complex structure such as structure 800 in
[0081] Similarly, anchor element 862 maintains conductive portion 812 in the correct place relative to carbon fibre reinforced composite elements 802 and 803, thereby ensuring that the conductive portion 812 performs the function of allowing electrical current to be relatively easily conducted between those carbon fibre reinforced composite elements, as well elements 806-807, which also abut conductive portion 812.
[0082] The same applies to the other conducting portions and respective anchor elements shown in
[0083]
[0084] The interlayer has a length, L.sub.1, which corresponds to the length of the reinforcing structure 800 and to the length of the carbon fibre reinforced composite elements. This length depends on the length of the blade. The length, L.sub.1, may for instance be in the range 60-95 m for a blade having a total length of 100 m.
[0085] The width W.sub.1 of the interlayer 831 corresponds to the width W.sub.1 of the first composite element layer illustrated in
[0086]
[0087] In
[0088] Detail 960 of
[0089]
[0090]
[0091] Similarly to
[0092] In
[0093] The structure in
[0094] Next, the second composite element layer, consisting of carbon fibre reinforced composite elements 805-807, is arranged on the interlayer 831 as per
[0095] This results in the reinforcing structure 800 shown in
[0096] Infusion and curing can then be performed in order to bond the carbon fibre reinforced composite elements together to form a single reinforcing unit.
[0097] The invention is not limited to the embodiments described herein and may be modified or adapted without departing from the scope of the present invention.
LIST OF REFERENCE NUMERALS
[0098] 2: wind turbine [0099] 4: tower [0100] 6: nacelle [0101] 8: hub [0102] 10: blades [0103] 14: blade tip [0104] 15: tip end [0105] 16: blade root [0106] 18: leading edge [0107] 20 trailing edge [0108] 30: root region [0109] 32: transition region [0110] 34: airfoil region [0111] 36: pressure side shell part [0112] 38: suction side shell part [0113] 40: shoulder [0114] 41: spar cap [0115] 42: fibre layers [0116] 43: sandwich core material [0117] 45: spar cap [0118] 46: fibre layers [0119] 47: sandwich core material [0120] 50: first shear web [0121] 51: sandwich core material [0122] 52: skin layers [0123] 55: second shear web [0124] 56: sandwich core material of second shear web [0125] 57: skin layers of second shear web [0126] 60: filler ropes [0127] 300: reinforcing structure [0128] 301-304: composite element [0129] 311: conductive portion of interlayer [0130] 331: interlayer [0131] 321: non-conductive portion of interlayer [0132] 421: non-conductive portion of interlayer [0133] 600: reinforcing structure [0134] 700: reinforcing structure [0135] 711: conductive portion of interlayer [0136] 712: anchor element [0137] 800: reinforcing structure [0138] 801-810: carbon fibre reinforced composite elements [0139] 811-816: conductive portions [0140] 821-823: non-conductive portions [0141] 831-833: interlayers [0142] 861-862: anchor elements [0143] 914-916: additional conductive portions [0144] 960: Detail of conductive portion with stiches [0145] 1016-1019: additional conductive portions [0146] 1171-1172: stitches [0147] D: largest dimension of a conductive portion [0148] L: length of wind turbine blade/longitudinal axis [0149] L.sub.1: length of reinforcing structure/composite elements [0150] r: distance from hub [0151] W.sub.1, W.sub.2: width of layers