Wind turbine blades and method of manufacturing the same

Abstract

Method of making a spar cap includes: providing a plurality of composite strips, each strip being of constant cross section defined by first and second sides and edges, the first and second sides comprising first and second abutment surfaces, the strip being of uniform thickness between the abutment surfaces, a first edge region of the strip comprising a first edge being of relatively reduced thickness, the first side of the strip comprising an edge surface, and the strip having a peel ply layer at least partially covering the first abutment surface and the edge surface; removing the peel ply layers; stacking the strips such that the first abutment surface abuts an abutment surface of an adjacent strip to define an interface region, such that a clearance region is defined; supplying resin to the respective clearance regions and causing the resin to infiltrate into the interface regions; and curing the resin.

Claims

1. A method of making a spar cap for a wind turbine blade, the method comprising: (a) providing a plurality of elongated pultruded fibrous composite strips, each strip being of essentially constant cross section taken transverse to a longitudinal axis of the strip and defined by first and second mutually opposed and longitudinally extending sides and by first and second longitudinal edges, the first and second sides comprising, respectively, first and second substantially planar abutment surfaces, a separation between the first and second sides defining a thickness of the strip, the strip being of essentially uniform thickness between the first and second abutment surfaces, a first edge region of the strip comprising a first edge of the strip being of relatively reduced thickness compared to a thickness of the strip between the first and second abutment surfaces, the first side of the strip comprising a first edge surface adjacent the first abutment surface in the first edge region of the strip, and the strip having a first peel ply layer at least partially covering the first abutment surface and at least partially covering the first edge surface; (b) removing the first peel ply layers from the plurality of strips; (c) stacking the strips in a mould such that the first abutment surface of each strip faces an abutment surface of an adjacent strip in the stack to define an interface region between the strips, and such that a clearance region is defined between the first edge region of each strip and an edge region of an adjacent strip in the stack; (d) supplying resin to the plurality of clearance regions and causing the resin to infiltrate into the interface regions between adjacent strips from the plurality of clearance regions; and (e) curing the resin to bond the strips together.

2. The method of claim 1, wherein the first abutment surface of each of the plurality of strips abuts an abutment surface of an adjacent strip in the stack to define the interface region between the strips.

3. The method of claim 1, wherein an interlayer is disposed in the interface region between the first abutment surface of each strip and the abutment surface of the adjacent strip in the stack.

4. The method of claim 1, wherein each of the plurality of strips is of tapering thickness in the first edge region, such that when the strips are stacked in step (c), the clearance region becomes progressively narrower moving from the first edge towards the interface region.

5. The method of claim 1, wherein the first edge surface is inclined relative to the first abutment surface.

6. The method of claim 1, wherein the first edge is a longitudinal edge of the strip.

7. The method of claim 1, wherein each strip has a second edge region of relatively reduced thickness, the second edge region comprising the second edge of the strip, and step (c) of the method comprises stacking the strips in the mould such that a clearance region is defined between the second edge region of each strip and an edge region of an adjacent strip in the stack.

8. The method of claim 7, wherein the first side of each strip comprises a second edge surface between the second edge and the first abutment surface, the second edge surface being inclined relative to the first abutment surface, and the first peel ply layer at least partially covers the second edge surface, and step (b) of the method comprises removing the first peel ply layer from the second edge surface.

9. The method of claim 1, wherein the second abutment surface of each strip is at least partially covered by a second peel ply layer, and step (b) of the method comprises removing the second peel ply layers from the respective strips to expose fibres on the respective second abutment surfaces; and step (c) of the method comprises stacking the strips in the mould such that the second abutment surface of each strip faces an abutment surface of an adjacent strip in the stack to define an interface region between the strips.

10. The method of claim 1, further comprising, prior to step (a), forming the strips by a pultrusion process comprising drawing a bundle of resin-coated fibres and the first peel ply layer through a pultrusion die having a cross section corresponding to the cross section of at least one of the plurality of strips taken transverse to a longitudinal axis thereof.

11. The method of claim 1, wherein step (c) comprises stacking the strips in a wind turbine blade mould.

12. The method of claim 1, wherein the first side of the strip comprises an outwardly extending step adjacent the first edge surface in the first edge region of the strip, wherein the first edge surface is arranged between the step and the first abutment surface.

13. The method of claim 12, wherein the step has a height that is essentially equal to a thickness of the first peel ply layer.

14. The method of claim 12, wherein the step is essentially orthogonal to the first edge surface.

15. The method of claim 1, wherein step (c) of the method comprises stacking the strips in the mould such that all of the strips stacked in the mould are aligned with each other.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIGS. 1, 2a and 2b have already been described above by way of background to the present invention. In order that the invention may be more readily understood, specific embodiments of the invention will now be described, by way of example only, with reference to the following drawings in which:

(2) FIG. 3a is a partial perspective view of a section of a pultruded fibrous composite strip having a peel ply layer on both sides of the strip in accordance with a first embodiment of the present invention;

(3) FIG. 3b is a partial plan view of the section of the pultruded fibrous composite strip of FIG. 3a;

(4) FIG. 4a is a partial cross-section of the pultruded fibrous composite strip of FIGS. 3a and 3b;

(5) FIG. 4b is a partial cross-section of the strip of FIGS. 3a and 3b arranged in a stack with an identical strip, and with the peel ply layers removed; and

(6) FIGS. 5a and 5b illustrate a method of manufacturing a wind turbine blade in accordance with the present invention.

DETAILED DESCRIPTION

(7) A pultruded fibrous composite strip typically has a thickness of approximately 5 mm, and a peel ply layer typically has a thickness of approximately 50 to 500 microns. It will be appreciated that the drawings provided are not scale representations, and particular features of the strip have been greatly exaggerated for illustrative purposes.

(8) FIGS. 3a, 3b and 4a show a pultruded fibrous composite strip 100 for stacking with one or more similar strips to make a spar cap for a wind turbine blade. The strip 100 is made of a fibre-reinforced plastic, and comprises unidirectional carbon fibres aligned in a resin matrix.

(9) The strip 100 is shaped substantially as a flat cuboid extending along a longitudinal axis L, the cuboid having a length substantially greater than its thickness or width. The strip 100 comprises first and second sides 102, 104 that extend longitudinally. The sides 102, 104 are joined by opposed transverse edges 106, 108 that are substantially perpendicular to the longitudinal axis L, and by opposed longitudinal edges 110, 112 that are aligned with the longitudinal axis L. Each side 102, 104 is at least partially covered by a peel ply layer 114 that can be removed to expose a roughened surface 116 on the respective side 102, 104 as shown in FIG. 4b.

(10) The spacing between the sides 102, 104 defines the thickness of the strip 100. The majority of the strip 100 is of substantially uniform thickness. In this way, the majority of each side 102, 104 is substantially flat. This flat majority of the strip 102, 104 defines an abutment surface 118. When the strip 110 is arranged in a stack, this abutment surface 118 abuts a facing abutment surface 118 of a neighbouring strip 100. Because the majority of the side 102, 104 is formed by the abutment surface 118, a large area of contact is provided between neighbouring strips 100. Maximising the area of contact in this way increases the strength of the bond between the neighbouring strips 100.

(11) As most clearly shown in FIGS. 3a and 4a, the strip 100 comprises an edge region 120 that includes one of the longitudinal edges 110 of the strip 100. The edge region 120 extends along the length of the longitudinal edge 110, and extends an orthogonal distance X into the strip 100 from the longitudinal edge 110. The edge region 120 of the strip 100 comprises an edge surface 122 that lies adjacent the abutment surface 118. This edge surface 122 extends between an edge 124 of the abutment surface 118 and a top corner 126 of the longitudinal edge 110, and features a step 140, which is explained in more detail later.

(12) The edge region 120 of the strip 100 is of reduced thickness relative to the majority of the strip 100. Specifically, the edge region 120 of the strip 100 is of tapering thickness, such that the edge surface 122 is inclined with respect to the abutment surface 118. The edge surface 122 meets the abutment surface 118 at an internal angle , which is less than 180, and greater than 90. The size of the angle may be determined in relation to other parameters of the strip 100, as will be further discussed, but is typically between 172 and 178.

(13) In the embodiment shown, a peel ply layer 114 is arranged on each of the upper and lower sides 102, 104, such that each peel ply layer 114 at least partially covers its respective side 102, 104. The peel ply layer 114 may be made from any suitable material such as coated or uncoated polyamide, fibreglass fabric or nylon. The peel ply layer 114 has a thickness t that is between approximately 50 microns and approximately 500 microns, and is preferably 150 microns.

(14) The peel ply layer 114 also comprises parallel edges 132 that extend longitudinally, and are aligned with the longitudinal axis (FIG. 3a) of the strip 110.

(15) The upper peel ply layer 114 covers the abutment surface 118 of the upper side 102, and extends partially into the edge region 120 to cover part of the edge surface 122 of the upper side 102. In this way, the peel ply layer 114 extends over the interface 124 between the abutment surface 118 and the edge surface 122. An edge portion 134 of the peel ply layer 114, partially covering the edge surface 122 of the strip 100, is therefore inclined with respect to a central portion 136 of the peel ply layer 100, covering the abutment surface 118 of the strip 100.

(16) Due to the pultrusion process previously described, the peel ply layer 114 cannot extend over the entirety of the edge surface 122. Put another way, the peel ply layer 114 stops short of the longitudinal edge 110 of the strip 100, so as to define a peripheral region 138 of the side 102, 104 that is not covered by the peel ply layer 114.

(17) The peripheral region 138 is located on the edge surface 122 of the strip 100, and lies adjacent to the longitudinal edge 110 of the strip 100. The peripheral region 138 extends between the upper corner 126 of the longitudinal edge of the strip 100, and an edge 132 of the peel ply layer 114. The peripheral region 138 extends into the strip 100 an orthogonal distance Y from the longitudinal edge 110 of the strip 100. Longitudinally, the peripheral region 138 extends along the entire length of the strip 100.

(18) Due to the pultrusion process, the peripheral region 138 of the edge surface 122 lies flush with an outer surface 130 of the peel ply layer 114. Thus, in the edge region 120 of the strip 100, the region of the edge surface 122 that is covered by the peel ply layer 114 lies inwardly of the peripheral region 138.

(19) At the interface between the peripheral region 138 of the edge surface 122 and the portion of the edge surface 122 that is covered by the peel ply layer 114, the edge surface 122 comprises a step 140 as mentioned above. The step 140 comprises a wall that is approximately orthogonal to the edge surface 122 and has a height that is equal to the thickness t of the peel ply layer 114. Either side of the step 140, the edge surface 122 is inclined at the same gradient. When the peel ply layer 114 is arranged on the strip 100, the edge 132 of the peel ply layer 114 abuts the wall of the step 140.

(20) It will be appreciated that, since the thickness t of the peel ply layer 114 is small (of the order of microns), the height of the step 140 is of a small magnitude. The step 140 shown in FIG. 4b is greatly exaggerated for illustrative purposes; in practice, the step 140 takes the form of a shallow indentation.

(21) Thus, moving from the abutment surface 118 of the strip 100 to the longitudinal edge 110 of the strip 100 (i.e. from right to left as shown in FIG. 4a), the upper side 102 of the strip 100 is initially horizontal to define the abutment surface 118. The abutment surface 118 meets the edge surface 122 at an angle , and the edge surface 122 tapers at a constant taper gradient such that it extends towards a central longitudinal plane of the strip 100. The edge surface 122 continues at the constant taper gradient until the step 140 in the edge surface 122. The step 140 in the edge surface 122 slopes steeply away from the central longitudinal plane of the strip 100, in a direction approximately orthogonal to the edge surface 122. The step height is equal to the thickness t of the peel ply layer 114. Beyond the step 140, the edge surface 122 continues into the peripheral region 138 at the same taper gradient. The peripheral region 138 of the edge surface 122 is inclined at the angle to the abutment surface 118, and terminates at the longitudinal edge 110 of the strip 100.

(22) In the embodiment shown, the lower, or second, side 104 of the strip 100 is a mirror-image of the upper side 102. Thus, all of the features described above in relation to the upper side 102 of the strip 100 apply to the lower side 104 of the strip 100. Hence the respective edge surfaces 122 of the strip 100 taper inwardly towards the longitudinal edge 110.

(23) Before the strip 100 is arranged in a stack to form a spar cap, the peel ply layers 114 are removed from the upper and lower sides 102, 104. When a peel ply layer 114 is removed from a side 102, 104 of the strip 100, a portion of the cured resin is removed from that side 102, 104. This removal of the resin forms a rough texture on the abutment surface 118 and on the part of the edge surface 122 that was covered by the peel ply layer 114.

(24) In the assembled spar cap, the strip 100, with the peel ply layer 114 removed, is arranged in a stack comprising similar strips 100, as shown in FIG. 4b. The abutment surface 118 of the strip 100 is arranged in abutment with a similar abutment surface 118 of a neighbouring strip 100 to define an interface region 142 between the strips 100. A thin layer of resin is interposed between adjacent strips 100 in the stack to bond the strips 100 together.

(25) When the strips are stacked, the tapered edge regions of the respective strips mean that the peripheral regions 138 of adjacent strips are spaced apart from each other such that a clearance region 144 is defined between the edge regions 120 of the neighbouring strips 100. Because of the tapered thickness of the edge region 120, the clearance region 144 becomes progressively narrower moving from the first longitudinal edge 110 towards the interface region 142. Expressed in other terms, the clearance region 138 becomes progressively wider moving from the interface region 142 towards the first edge 110. In the assembled spar cap, this clearance region 144 is filled with resin.

(26) In the embodiment shown, the neighbouring strip 100 is identical to the first strip 100. The clearance region 144 is therefore defined between the respective narrowed edge regions 102 of the neighbouring strips 100.

(27) To make a spar cap from the strips 100, the peel ply layers 114 are removed from the desired number of strips 100, and the strips 100 are stacked in a mould such that their abutment surfaces 118 are aligned and abut one another. Resin is then introduced into the mould, and the resin infuses into the clearance regions 144 that are defined between neighbouring strips 100.

(28) The narrowing of the clearance region 144 towards the interface region 142 of the strips 100 provides an advantageous funnel effect whereby a relatively large inlet for resin is created between adjacent stacked strips 100, and the tapering clearance region 144 serves to concentrate and guide the resin towards the interface region 142 between the strips 100.

(29) The flow of resin into the interface regions 142 is also assisted by the roughened texture 116 of the abutment surfaces 118 and of the adjacent part of the edge surface 122, which gives rise to capillary action to enhance resin infusion.

(30) After the resin has infiltrated into the interface region 142 between the strips 100, the resin is cured to bond the strips 100. The resin may be cured, for example, by heating the stack of strips 100.

(31) The spar cap 146 may be made in a dedicated mould, so as to form a pre-cured spar cap 146 to be integrated into a wind turbine blade at a later stage. Alternatively, the spar cap 146 may be formed and integrated into the wind turbine blade simultaneously with the manufacture of the blade itself. A method of making a wind turbine blade in accordance with the present invention will now be described with reference to FIGS. 5a and 5b.

(32) Referring to FIGS. 5a and 5b, the turbine blade comprises a windward shell 148 and a leeward shell (not shown), each manufactured in respective half-moulds 150. During manufacture of each shell 148, an outer skin 152 in the form of a dry fibre material is first placed on a surface of the half-mould 150. The strips 100 are then positioned in the mould 150.

(33) Next, a layer of structural foam 154 is introduced into the half-mould 150 to fill the regions between the spar caps 146. An inner skin 156, in the form of a dry fibre material, is then placed on the upper surfaces of the spar caps 146 and the structural foam 154. The components are covered with an airtight bag 158 to form an evacuation chamber encapsulating all of the components.

(34) The chamber is then evacuated using a vacuum pump 160. With the pump 160 still energised, a supply of liquid resin 162 is connected to the chamber, and resin flows into the chamber through a plurality of resin inlets, which are longitudinally spaced along the mould. Resin infuses throughout the mould in a generally chordwise direction. The resin infuses into the clearance regions 144 located between edge regions 120 of neighbouring strips 100. Resin is delivered to the clearance regions 144 along the entire length of each stack, and infuses between the strips 100 in each stack via the roughened surfaces 116. In this way, the resin need only infuse a relatively short distance in a direction extending from one longitudinal edge 110 of the strip 100 to the other longitudinal edge 112. Resin also infuses between other components in the half shell 148.

(35) The pump 160 continues to operate during a subsequent moulding operation in which the mould 150 is heated so as to cure the resin, although during the curing process the vacuum pressure may be adjusted.

(36) Shear webs are then attached to the inner skin 156 immediately above the spar caps 146 in the lower half-mould 150, and the upper free ends of the webs are coated with respective layers of adhesive.

(37) The upper half-mould is then pivoted into position above the lower half-mould 150, such that the upper half-mould is upturned and placed on top of the lower half-mould 150. This causes the spar caps 146 within the upper half-mould to adhere to the upper free ends of the shear webs. The resilient nature of the webs gives rise to a biasing force of the webs against the upper spar caps 146 so as to ensure good adhesion.

(38) The mould is then opened, and the finished turbine blade lifted from the mould. The resulting turbine blade is then incorporated into a wind turbine by known methods.

(39) Each pultruded fibrous composite strip 100 is made by a pultrusion process in which resin-coated fibres are drawn through a die in a process direction together with a pair of peel ply layers 114. As the components are drawn through the die, the peel ply layers 114 are arranged so as to be located on respective upper and lower sides 102, 104 of the strip 100.

(40) During the pultrusion process, an edge region 120 of the strip 100 is shaped such that its thickness is less than the thickness of the majority of the strip 100. This is achieved by shaping the die to reflect the desired cross section of the strip 100.

(41) Specifically, the die has a cross section transverse to the process direction that is defined by opposed major faces that are joined by opposed minor faces. The spacing between the major faces defines the height of the die. The majority of the die is of substantially uniform height, while edge regions of the die, corresponding to the edge regions 120 of the strip 100, are of relatively reduced height compared to the majority of the die.

(42) As the fibres and peel ply layers 114 are drawn through the die, the die shapes the fibres and peel ply layers 114 into the desired shape of the strip 100. As previously described, the peel ply layers 114 are arranged respectively on both sides 102, 104 of the strip 100, but do not extend to the longitudinal edges 110, 112 of the strip 100, so as to leave the fibres of the peripheral regions 138 uncovered. As the peel ply layers 114 and fibres are drawn through the die, they are shaped by the die, and lie against the die surfaces. The peel ply layers 114 and the fibres of the peripheral regions 138 of the strip 100 therefore lie flush with one another.

(43) The die is heated as the components are drawn through it, so as to cure the strip 100 in a continuous pultrusion process. The peel ply layers 114 are cured into the resin on the sides 102, 104 of the strip 100. In this way, when the peel ply layers 138 are removed, a portion of the resin from the side 102, 104 of the strip 100 is removed, leaving a roughened texture as described above.

(44) Many modifications may be made to the embodiments described above without departing from the scope of the invention as defined in the following claims.

(45) Whilst in the example described above peel ply layers are arranged on each of the upper and lower sides, it will be appreciated that this need not be the case, and a peel ply layer may cover only the upper side, or only the lower side of the strip. Whilst in the example described above both the edge surface of the upper side, and the edge surface of the lower side are inclined with respect to the abutment surface, in an alternative embodiment of the invention only one of the respective edge regions may be inclined.

(46) Furthermore, in the example described above the strip may comprise a single, first tapered edge region that comprises a first longitudinal edge. Alternatively, however, the strip may comprise first and second tapered edge regions, the first edge region comprising the first longitudinal edge and the second edge region comprising the second, opposed longitudinal edge. The second edge region may comprise all the features described with regard to the first edge region described above.

(47) It is also envisaged that, alternatively or additionally, one or both transverse edges of the strip may be provided with reduced thickness as previously described. In this case the edge regions would additionally or alternatively comprise a transverse edge of the strip. In the stack of strips, clearance regions would then be provided between transverse edge regions, and resin would infuse into the interface region longitudinally.

(48) In the embodiment of the spar cap described, each strip in the stack is a strip according to the invention, such that each strip comprises an edge region of relatively reduced thickness. However, this need not be the case, and embodiments are envisaged in which strips of substantially uniform thickness that do not comprise edge regions of relatively reduced thickness are also included in the stack. For example, strips of substantially uniform thickness may be interposed between strips having edge regions of relatively reduced thickness. In this way, clearance regions may still be defined between adjacent strips, such that resin can infiltrate between adjacent strips.