STRUCTURAL MAT FOR REINFORCING A WIND TURBINE BLADE STRUCTURE, A WIND TURBINE BLADE AND A METHOD FOR MANUFACTURING A WIND TURBINE BLADE

Abstract

The invention relates to a structural mat for reinforcing a wind turbine blade structure. The structural mat comprises two or more groups of bonded fibres, the fibres being bonded by a matrix substantially preventing relative movement of said fibres and wherein said groups are connected to each other by connection means limiting the relative movement of said groups. The invention further relates to a wind turbine blade and a method for manufacturing a wind turbine blade.

Claims

1-18. (canceled)

19. A method of manufacturing a wind turbine blade of generally hollow construction and formed from first and second opposing half-shells, the method comprising: constructing each half-shell from an inner skin and an outer skin; locating at least one reinforcing structure on the outer skin so as to extend along the lengthwise direction of the blade, each of the at least one reinforcing structure comprising a stack of layers, each stack having a thickness which extends in a direction substantially perpendicular to a surface of the blade, each layer extending across a width of the respective stack, the width being perpendicular to the lengthwise direction of the blade and perpendicular to the thickness of the stack, and each layer comprising at least one pre-cured pultruded fibrous composite strip; disposing within each half-shell core material on the outer skin so as to extend: (a) from the at least one elongate reinforcing structure towards a leading edge of the blade; and (b) from the at least one elongate reinforcing structure towards a trailing edge of the blade; disposing the inner skin on upper surfaces of the at least one elongate reinforcing structure and the core material; and disposing an elongate web so as to extend between the at least one reinforcing structure in the first half-shell and the at least one reinforcing structure in the second half-shell.

20. A method of manufacturing a wind turbine blade of generally hollow construction and comprising first and second half-shells, the method comprising: disposing, in each of a first and second elongated half-mould, one or more fibre cloths for respective outer skins; locating, in each of the first and second elongated half-moulds, at least one elongate reinforcing structure on the fibre cloths for the outer skins so as to extend along the lengthwise direction of the respective half-moulds, each of the at least one reinforcing structure comprising a stack of layers, each stack having a thickness which extends in a direction substantially perpendicular to a surface of the respective half-mould, each layer extending across a width of the respective stack, the width being perpendicular to the lengthwise direction of the respective half-mould and perpendicular to the thickness of the stack, and each layer comprising at least one pre-cured pultruded fibrous composite strip; disposing within each of the respective half-moulds core material on the fiber cloths for the outer skin so as to extend: (a) from the at least one elongate reinforcing structure towards a leading edge of the respective half-mould; and (b) from the at least one elongate reinforcing structure towards a trailing edge of the respective half-mould; disposing, in each of the first and second elongated half-moulds, on upper surfaces of the at least one reinforcing structure and the core material, one or more fibre cloths for respective inner skins; supplying resin into the first and second half-moulds; and subsequently curing the resin so as to form the first and second half-shells.

21. The method of claim 20, further comprising: subsequently disposing an elongate web in one of the half-moulds; and pivoting the first half-mould into a position above the second half-mould, so as for the elongate web to extend between the at least one reinforcing structure in the first half-shell and the at least one reinforcing structure in the second half-shell.

22. A wind turbine blade of generally hollow construction, comprising: first and second opposing half-shells, each half-shell comprising: an inner skin; an outer skin; at least one reinforcing structure being located between the inner and outer skins, each of the at least one reinforcing structure extending along a lengthwise direction of the blade and comprising a stack of layers, each stack having a thickness which extends in a direction substantially perpendicular to a surface of the blade, each layer extending across a width of the respective stack, the width being perpendicular to the lengthwise direction of the blade and perpendicular to the thickness of the stack, and each layer comprising at least one pre-cured pultruded fibrous composite strip; and core material disposed between the inner and outer skins and extending: (a) from the at least one reinforcing structure towards a leading edge of the blade; and (b) from the at least one reinforcing structure toward a trailing edge of the blade; and an elongate web extending between the at least one reinforcing structure in the first half-shell and the at least one reinforcing structure in the second-half shell.

23. The wind turbine blade of claim 22, wherein the at least one elongate reinforcing structure and the core material define abutment edges which are substantially perpendicular to the surface of the wind turbine blade.

24. The wind turbine blade of claim 22, wherein the layers are of different lengths such that the thickness of the stack is tapered towards at least one end.

25. The wind turbine blade of claim 24, wherein at least one of the two ends of each layer is chamfered.

26. The wind turbine blade of claim 22, wherein each layer comprises a plurality of pultruded fibrous composite strips

27. The wind turbine blade of claim 26, wherein the plurality of pultruded fibrous composite strips comprises a parallel configuration of strips within the layers.

28. The wind turbine blade of claim 27, wherein the longitudinal inner edges of the strips within each layer of the stack are staggered with respect to the inner longitudinal edges of the strips within the or each adjacent layer.

29. The wind turbine blade of claim 28, wherein the plurality of pultruded fibrous composite strips comprises a plurality of strips arranged end to end.

30. The wind turbine blade of claim 22, wherein the pultruded fibrous composite strips are formed from fibers selected from: natural fibers; metal fibers; mineral fibers; cellulose-based fibers; polymer fibers; glass fibers; aramid fibers; and/or carbon fibers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0083] The invention will be described in the following with reference to the figures in which

[0084] FIG. 1 illustrates a large modern wind turbine as known in the art,

[0085] FIG. 2 illustrates a group of bonded fibres, as seen from the end,

[0086] FIG. 3 illustrates a structural mat comprising connection means, as seen in perspective,

[0087] FIG. 4 illustrates a structural mat comprising stitching means, as seen in perspective,

[0088] FIG. 5 illustrates a structural mat comprising tapered side regions, as seen from the end of the mat,

[0089] FIG. 6 illustrates a structural mat comprising a tapered end region, as seen in perspective,

[0090] FIG. 7 illustrates a structural mat comprising more than one layer of groups, as seen in perspective,

[0091] FIG. 8 illustrates a structural mat comprising groups of varying cross-section, as seen from the top,

[0092] FIG. 9 illustrates different embodiments of groups with a shape comprising more than three different axes of symmetry, as seen in perspective,

[0093] FIG. 10 illustrates different embodiments of groups with a shape comprising three or less different axes of symmetry, as seen in perspective,

[0094] FIG. 11 illustrates a wind turbine blade comprising structural mats, as seen from the top,

[0095] FIG. 12 illustrates a cross-section of a wind turbine blade comprising structural mats, as seen from the root of the blade,

[0096] FIG. 13 illustrates a cross section of a first blade mould and a second blade mould placed beside each other, as seen from the root of the blade, and

[0097] FIG. 14 illustrates a cross section of a closed wind turbine blade mould, as seen from the root of the blade.

DETAILED DESCRIPTION

[0098] FIG. 1 illustrates a large modern wind turbine as known in the art,

[0099] FIG. 1 illustrates a modern wind turbine 1, comprising a tower 2 and a wind turbine nacelle 3 positioned on top of the tower 2. The wind turbine rotor 4, comprising three wind turbine blades 5, is connected to the nacelle 3 through the low speed shaft which extends out of the nacelle 3 front.

[0100] FIG. 2 illustrates a group 7 of bonded fibres 21, as seen from the end.

[0101] In this embodiment of the invention the group 7 of bonded fibres 21 is formed as a substantially equilateral square with rounded corners but as explained later e.g. in relation with FIG. 9 an 10 the cross-section of the groups 7 can be shaped in a multitude of ways.

[0102] In this embodiment the group 7 comprises a number of evenly spaced fibres 21 fixed in the group 7 by a matrix 8 which in this embodiment is cured resin however, it is obvious to the skilled person that the fibres 21 could be arranged and distributed differently within the group 7.

[0103] In this simplified illustration of a group 7 the fibres 21 only constitutes a fraction of the total cross-sectional area of the group 7 but in a preferred embodiment of the invention the fibres 21 would constitute between 10% and 99%, preferably between 25% and 90% and most preferred between 45% and 85% of the total cross-sectional area of the group 7. Most often the fibres 21 would constitute at least 50% of the cross section area of the group.

[0104] In this embodiment the sides of the group 7 are straight but in another embodiment the sides might be slightly curved e.g. to allow for a more easy penetration of infusion resin.

[0105] The group 7 could be made in a number of ways but in a preferred embodiment the group 7 is made by pultrusion.

[0106] Pultrusion is a manufacturing process for producing continuous lengths of Fibre Reinforced Polymer (FRP) structural shapes. Raw materials could include a matrix 21 in the form of a liquid resin mixture (e.g. containing resin, fillers and specialized additives) and reinforcing fibres 21. The process involves pulling these raw materials (rather than pushing as is the case in extrusion) through a heated steel forming die using a continuous pulling device. The reinforcement materials are in continuous forms such as rolls of fibreglass tape or doffs of fibreglass roving. As the reinforcements are saturated with the resin mixture in a resin impregnator and pulled through the die, the curing (or hardening) of the resin is initiated by the heat from the die and a more rigid, cured group 7 is formed that substantially corresponds to the shape of the die.

[0107] In this embodiment the fibres 21 are glass fibres 21 but in another embodiment the fibres 21 could be any other kind of natural, mineral, metal or other fibre 21 suitable for reinforcing groups 7 according to the invention.

[0108] Likewise, the matrix 8 bonding the fibres 21 in the group 7 is in this embodiment a synthetic thermoset resin but in another embodiment the matrix 8 could be any kind of natural and/or synthetic resin suitable for bonding the fibres 21 in the group 7.

[0109] In this embodiment the group 7 has a height and width of approximately 4 millimetres but in another embodiment of the invention the groups 7 could have a height and width of between 0.1 and 20 mm, preferably between 0.2 and 12 mm and most preferred between 0.5 and 8 mm.

[0110] FIG. 3 illustrates a structural mat 6 comprising connection means 9, as seen in perspective.

[0111] In this embodiment of the invention the structural mat 6 comprise seven evenly spaced, aligned and neighboring groups 7 of bonded fibres 21 held together by connection means 9 in the form of a transverse string of rubber or rubber-like material connected to all the groups 7.

[0112] In this embodiment the mat 6 has a transverse width W of approximately 40 millimeters but in another embodiment the mat 6 could be between 1 and 5000 mm, preferably between 10 and 1000 mm and most preferred between 50 and 500 mm wide.

[0113] If the mat 6 is made too wide it might be difficult to fit in the blade 5 and if it is too narrow the manufacturing process might be more complicated if more parallel lengths of mats had to be laid out in the blade 5 to offer sufficient reinforcement.

[0114] In another embodiment the structural mat 6 could also be made with varying width W or thickness throughout its entire length e.g. to adapt the mat 6 specifically to the specific contours of a specific blade type.

[0115] In this embodiment the gap between the groups 7 is approximately 0.5 millimeters but in a preferred embodiment the gap would only be around 0.1 mm which just would be enough to allow for resin to pass in between the groups 7 during an infusing process when the mat 6 is placed in a blade mould 26, 27 when the blade 5 is being manufactured. It is advantageous if the gap is maintained at e.g. 0.1 mm throughout the entire longitudinal extent of the mat 6 in that if the gap is much smaller the risk of locking off resin during the infusion process is increased and if the gap is too large resin consumption would increase.

[0116] The connection means 9 should preferably substantially maintain the mutual transverse position of the groups 7 so that the gap is maximum 0.5 mm but at the same time allow for a little mutual displacement in the longitudinal direction of the groups 7 between 1 and 5 millimeters preferably around 2.5 millimeters to ensure that the mat 6 is flexible enough to follow the complex contour of the blade 5.

[0117] FIG. 4 illustrates a structural mat 6 comprising stitching means 14, as seen in perspective.

[0118] In this embodiment of the invention the connection means 9 is stitching means 14 in the form of a thread 22 zig-zagging in and out between the groups 7 to stitch the groups together.

[0119] The stitching means 14 could in another embodiment also be one or more threads 22 tying e.g. two of the groups together and other threads 22 would then tie one of said two groups 7 to a neighboring group 7, which then by other threads 22 would be tied to the next neighboring group and so on.

[0120] The thread 22 used for stitching the groups 7 together are in this embodiment a string of polyester but in another embodiment the threads 22 could be made from any kind of natural or synthetic material such as nylon, roving of natural or synthetic fibres or any combination thereof.

[0121] In this embodiment connection means 9 are connecting the groups 7 for every 100 mm of the mat 6 in the longitudinal direction of the groups 7 but in another embodiment the connection means 9 could be placed closer or further apart e.g. depending on the module of elasticity of the groups 7, the cross sectional area of the groups 7, the complexity of the surface in the blade 5 which the mat 6 has to adapt to or any combination thereof.

[0122] FIG. 5 illustrates a structural mat 6 comprising tapered side regions 12, as seen from the end of the mat 6.

[0123] The groups 7 of the mats 6 illustrated in FIGS. 3 and 4 have all been substantially identical i.e. they have substantially the same cross sectional shape and the same length but in this embodiment of the invention both the length and the cross sectional shape of the groups 7 vary throughout the mat 6.

[0124] To avoid or reduce local stress concentrations along the sides of the mat 6 and e.g. to ensure a gradual change of the stiffness in the blade 5, the structural mat 6 is in this embodiment provided with tapered side regions 12 in the form of triangular sideward pointing groups 7 placed outermost at both sides of the mat 6.

[0125] In another embodiment the mat 6 could only comprise tapered side regions 12 at one side of the mat 6 or only parts of the longitudinal extend of the mat 6 could be provided with one or two tapered side regions 12.

[0126] In this embodiment the mat 6 is also provided with a particularly wide group 7 at the centre. The wide group 7 only extends for a certain length of the longitudinal extend of the mat 6 to ensure high stiffness of the mat 6 at certain parts and e.g. reduce use of material or to ensure transverse flexibility of the mat 6 where the wide group 7 is not present.

[0127] FIG. 6 illustrates a structural mat 6 comprising a tapered end region 11, as seen in perspective.

[0128] Likewise, to avoid or reduce local stress concentrations at the end of the mat 6 and e.g. to ensure a gradual change of the stiffness in the blade 5 the structural mat 6 is in this embodiment provided with a tapered end regions 11 in that the height of the groups gradually decreases.

[0129] In this embodiment the groups 7 are of uniform length but in another embodiment the groups 7 could be of varying length e.g. making the end of the mat 6 pointy at the centre or at the sides e.g. to adapt to the narrowing shape of the wind turbine blade 5.

[0130] FIG. 7 illustrates a structural mat 6 comprising more than one layer 10 of groups 7, as seen in perspective.

[0131] In this embodiment the mat 6 comprises two substantially uniform layers 10 but in another embodiment the mat 6 could comprise three, four, five or more layers 10 and each layer 10 could be formed differently from the next.

[0132] In this embodiment the layers 10 are connected by the same connection means 9 connecting the groups in the individual layers 10 in that the stitching means 14 connects the groups 7 next to and above or below each group 7 to said group 7.

[0133] In another embodiment the layers 10 could be connected by separate connection means 9 such as separate stitching means 14, separate clamps, strategically placed dots of glue or other.

[0134] In this embodiment of the invention all the groups 7 in all the layers 10 run substantially parallel but another embodiment of the invention one or more layers 10 could be placed in an angle in relation to one or more further layers 10 of the mat 6. For example one or more layers 10 could be placed in an angle of between 0 and 90 in relation to one or more other layers 10 to give desired blade stiffness properties in specific directions.

[0135] FIG. 8 illustrates a structural mat 6 comprising groups 7 of varying cross-section, as seen from the top.

[0136] In this embodiment the cross sectional shape of all the groups 7 of a mat 6 diverge over the same longitudinal extend of the mat 6 e.g. to save material, to increase the transverse flexibility of the mat 6 to better adapt to a sharp turn in the blade 5 and/or to change blade stiffness as required along the blade 5.

[0137] In another embodiment the cross sectional area of the groups 7 could change also or instead, only some of the groups 7 could have varying cross sectional area and/or shape or the area and/or the shape could vary over different lengths.

[0138] FIG. 9 illustrates different embodiments of groups 7 with a shape comprising more than three different axes of symmetry 13, as seen in perspective.

[0139] Circular groups 7, square groups 7 and polygonal groups with at number of sides larger than four all comprise more than three different axes of symmetry 13 ensuring that the bending qualities are substantially uniform no matter if the mat 6 is strained up and down or sideways.

[0140] In this embodiment the height and the width (or the diameter) of the groups 7 are five millimeters and the stiffness EI of the groups is 1.6 Nm.sup.2, making a 300 mm long cantilevered group 7 deflect 6 millimeters when subject to a load of 100 grams at the free end of the group 7.

[0141] However within a certain range the height, the width and the stiffness can be varied infinitely and in the below table this range is definedwhere the stiffness EI is the product of the elastic modulus E and the second moment of inertia I of the groups 7.

[0142] The deflection column provides examples of deflections when straining the group 7 with a 100 grams mass at the end of the group 7.

TABLE-US-00001 Group Group Group Stiffness Length Width Thickness EI Deflection m m m Nm.sup.2 m Most preferred 0.3 0.0028 0.0028 0.15 0.057 range 0.3 0.005 0.005 1.6 0.006 More preferred 0.3 0.0014 0.0014 0.03 0.919 range 0.3 0.008 0.008 35 0.0003 Preferred range 0.3 0.0014 0.0014 0.01 0.276 0.3 0.015 0.015 420 0.0000

[0143] In this embodiment the groups 7 are all illustrated with sharp edges but in another embodiment the edges would be rounded and/or the sides might be slightly convex i.e. be slightly curved outwards e.g. to allow for a more easy penetration of infusion resin.

[0144] FIG. 10 illustrates different embodiments of groups 7 with a shape comprising three or less different axes of symmetry 13, as seen in perspective.

[0145] It is feasible that different bending qualities could be needed for bending in different directions and for this purpose the illustrated triangular, oval and rectangular groups 7 could be advantageous, in that these groups 7 all comprises three or less different axes of symmetry 13.

[0146] FIG. 11 illustrates a wind turbine blade 5 comprising structural mats 6, as seen from the top.

[0147] In this embodiment of the invention the illustrate wind turbine blade 5 comprises a leading edge 17, a trailing edge 18, a tip 19 and a root 20.

[0148] The blade is typically hollow, except for one or more strengthening members 16 extending substantially the entire length of the blade 5 or part of the blades 5 length. A wind turbine blade 5 known in the art is typically made of a glass fibre and resin composite reinforced by carbon fibre, carbon fibre reinforced wood or a combination hereof.

[0149] In this embodiment of the invention the blade 5 is provided with structural mats 6 substantially along the entire length of the load carrying structure along the trailing edge 18, the leading edge 17 and the strengthening member 16 but in another embodiment the mats could only be placed along one of the load carrying structures of the blade 5 or along parts of one or more of the load carrying structures.

[0150] FIG. 12 illustrates a cross-section of a wind turbine blade 5 comprising structural mats 6, as seen from the root 20 of the blade 5.

[0151] A wind turbine blade 5 known in the art is typically made of different kinds of material 23 in different kinds of layers usually interconnected by resin. In this embodiment the structural mats 6 are incorporated into and/or in between the other layers of blade material 23 but in another embodiment the mats 6 could be placed on top of the other blade material 23.

[0152] In this embodiment the thickness of the shell of the blade 5, comprising the blade material 23 and the structural mats 6, is substantially uniform in the entire width of the blade 5 but in a preferred embodiment the thickness would vary and particularly around the load carrying structure where structural mats 6 are placed the blade shell could be thicker than other parts of the blade shell.

[0153] In this embodiment of the invention mats 6 are arranged in the load carrying structure along the trailing edge 18, the leading edge 17 and the strengthening members 16 in both halves 24, 25 of the blade 5 but in another embodiment the mats 6 could only be placed in one of the blade halves 24, 25 or the mats 6 could be placed more asymmetrically in the blade halves 24, 25.

[0154] FIG. 13 illustrates a cross section of a first blade mould 26 and a second blade mould 27 placed beside each other, as seen from the root 20 of the blade 5.

[0155] In this embodiment a first blade half 24 is being moulded in a first blade mould 26 and a second blade half 25 is being moulded in a second blade mould 27.

[0156] Many different wind turbine blades 5 are known in the art and there are therefore also many different ways of manufacturing wind turbine blades 5 but one method for making wind turbine blades 5 includes preparing the moulds 26, 27 e.g. by coating the moulds 26, 27 with a release coat for ensuring that the finished blade 5 can be removed form the moulds 26, 27, providing a layer of gel coat which ensure a smooth surface of the blade 5 and other. Hereafter the actual blade structure is build by adding one or more layers of blade material 23 to the moulds 26, 27, where the blade material could be nonwoven or woven, dry or pre-impregnated fiberglass mats.

[0157] According to the invention the moulds 26, 27 could hereafter be added one or more strategically placed structural mats 6 comprising two or more connected groups 7 of bonded fibres 21, which will reinforce and stiffen the blade 5.

[0158] Hereafter the moulds 26, 27 could be provided with additional layers of blade material 23 to encapsulate the structural mats 6 in the blade material 23.

[0159] Resin could now be infused to rigidly connect the structural mats 6, the blade material 23 and e.g. other parts of the blade halves 24, 25 to form a single blade half 24, 25.

[0160] During the manufacturing process the blade 5 could also be provides with other kinds of blade material 23 and reinforcements e.g. made of wood, concrete, metal, polystyrene foam or other and further wind turbine blade manufacturing steps could be performed.

[0161] In this embodiment of the invention the moulds 26, 27 are for moulding an entire wind turbine blade 5, but since wind turbines 1 are getting larger and larger, the wind turbine blades 5 could be too long to be transported in one piece. The blade 5 would then be manufactured as sections, which then are to be assembled at the wind turbine mounting site.

[0162] FIG. 14 illustrates a cross section of a closed wind turbine blade mould 26, 27, as seen from the root 20 of the blade 5.

[0163] When the blade halves 24, 25 have hardened, two strengthening members 16 can be attached to the first blade half 24 e.g. by means of adhesive before the joint area 15 of the blade halves 24, 25 are provided with an adhesive, and the first blade half 24 including the first blade mould 26 is placed on top of the second blade half 25 and mould 27.

[0164] When the second blade half 25 is placed on top of the first 24, and the strengthening members 16 are attached to the second blade half 25, the strengthening members 16 constitutes cross braces making the blade 5 more rigid and helping the blade 5 maintain its shape.

[0165] In another embodiment the blade 5 could be provided with more or less than two juxtaposed strengthening members 16 e.g. one, three, four or six members or the wind turbine blade halves 24, 25 could be made so strong that no strengthening members 16 was needed.

[0166] After the blade halves 24, 25 have been brought together pressure is applied while the adhesive in the joint areas 15 hardens, where after the blade 5 is removed from the moulds 26, 27 and final touches are made such as removing excess material along the blade joints areas 15, polishing the blade 5 and other.

[0167] The invention has been exemplified above with reference to specific examples of wind turbine blades 5, groups 7, structural mats 6, wind turbine blade manufacturing methods and other. However, it should be understood that the invention is not limited to the particular examples described above but may be designed and altered in a multitude of varieties within the scope of the invention as specified in the claims.

LIST

[0168] 1. Wind turbine [0169] 2. Tower [0170] 3. Nacelle [0171] 4. Rotor [0172] 5. Blade [0173] 6. Structural mat [0174] 7. Group of bonded fibres [0175] 8. Matrix [0176] 9. Connection means [0177] 10. Layer of groups [0178] 11. Tapered end region [0179] 12. Tapered side region [0180] 13. Axis of symmetry [0181] 14. Stitching means [0182] 15. Joint area of blade halves [0183] 16. Strengthening member [0184] 17. Leading edge [0185] 18. Trailing edge [0186] 19. Tip edge [0187] 20. Root [0188] 21. Fibre [0189] 22. Thread [0190] 23. Blade material [0191] 24. First blade half [0192] 25. Second blade half [0193] 26. First blade mould [0194] 27. Second blade mould [0195] W. Width of mat