MOULD AND METHOD TO BUILD UP A BLADE

Abstract

Manufacturing a blade by arranging a plurality of layers are in a mould. A matrix material is injected, through an inlet which is partly integrated into an inner surface of the mould, into the plurality of layers injecting the matrix material.

Claims

1. A method for manufacturing a blade, comprising: arranging a plurality of layers with a total permeability for a matrix material in a mould; the mould comprising a first portion and a second portion, the arranging comprises positional a first subset of the plurality of layers on the first portion and a positioning a second subset of the plurality of layers on the second portion, the second subset having a higher permeability than the first subset; injecting the matrix material into a laminated structure formed by the plurality of layers to build up the blade; and injecting the matrix material through an inlet which is partly integrated into an inner surface of the mould.

2. The method as claimed in claim 1, comprising: guiding the injected matrix material through a flow duct which is at least partly integrated into the inner surface of the mould.

3. The method as claimed in claim 1, wherein the injected matrix material is injected through the inlet located at the first portion.

4. The method as claimed in claim 1, wherein the mould comprises a main beam portion for building up a main beam of the blade, and the matrix material is injected through an inlet which is located at the main beam portion, and/or the matrix material is guided through a flow duct which is located at the main beam portion.

5. The method as claimed in any of the claims 1, wherein the blade comprises a root and a tip, and the mould comprises a root end corresponding to the root of the blade and a tip end corresponding to the tip of the blade, and the matrix material is injected through an inlet at a position along a length from the root end to the tip end of the mould of between 0.25 and 0.5 of a total blade length measured from the blade root.

6. The method as claimed in any of the claims 1, wherein the blade comprises a root and a tip, and the mould comprises a root end corresponding to the root of the blade and a tip end corresponding to the tip of the blade, and the matrix material is injected in a flow duct at a position along a length from the root end to the tip end of the mould of between 0.25 and 0.5 of a total blade length measured from the blade root.

7. The method as claimed in claim 1, wherein the matrix material is injected with a pressure higher than atmospheric pressure.

8. The method as claimed in claim 7, wherein the matrix material is injected with a pressure between atmospheric pressure and a maximal pressure, and wherein a difference between the atmospheric pressure and the maximal pressure is a pressure drop across the laminated structure formed by the plurality of layers.

9. The method as claimed in claim 2, wherein the matrix material is injected with a pressure depending on a local permeability of the laminated structure formed by the plurality of layers adjacent to the inlet and/or flow duct.

10. The method as claimed in claim 9, wherein the mould comprises a plurality of inlets and/or a plurality of flow ducts, and the matrix material is injected through each inlet and/or guided through each flow duct with an individual pressure depending on the local permeability of the laminated structure formed by the plurality of layers adjacent to the inlet and/or flow duct.

11. The method as claimed in claim 1, wherein matrix material is injected with a first pressure through an inlet which is located at the first portion, wherein matrix material is injected with a second pressure through an inlet which is located at the second portion, and wherein the first pressure is higher than the second pressure.

12. The method as claimed in claim 2, wherein the flow duct comprises a lining.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0080] Further features, properties and advantages will become clear from the following description of embodiments in conjunction with the accompanying drawings. They show preferred configurations and do not limit the scope of the invention. All mentioned features are advantageous alone or in any combination with each other.

[0081] FIG. 1 shows the arrangement according to the invention in a schematically view,

[0082] FIG. 2 shows, in reference to FIG. 1, a preferred configuration of the invention,

[0083] FIG. 3 shows, in reference to FIG. 1 and to FIG. 2, the flow of the matrix material,

[0084] FIG. 4 shows a part of the blade, where surplus matrix material extends from the surface of the blade,

[0085] FIG. 5 shows in reference to FIG. 1 a flow duct, which contains a lining according to the invention,

[0086] FIG. 6 shows a part of the blade, where surplus matrix material extends from the surface of the blade, if a lining is used according to the invention, and

[0087] FIG. 7 shows different cross sections of the lining, referring to FIG. 6.

[0088] FIG. 8 schematically shows a wind turbine.

[0089] FIG. 9 shows a rotor blade in a plan view on the plane defined by the blade's span and the blade's chord.

[0090] FIG. 10 shows a chord-wise cross section through the rotor blade's airfoil section.

[0091] FIG. 11 schematically shows the resin flow from the inlet channel through the laminated structure in a sectional view.

[0092] FIG. 12 schematically shows part of the mould covered with a laminated structure and a vacuum bag in a sectional view.

[0093] FIG. 13 schematically shows an inventive closed mould arrangement in a sectional view.

[0094] FIG. 14 schematically shows a wind turbine rotor blade 15 in a sectional view along the plane defined by the blade's span and the blade's cord.

[0095] FIG. 15 schematically shows an advantageous positioning of the flow duct in part of a mould in a sectional view.

[0096] FIG. 16 schematically shows a positioning of flow ducts depending on the permeability of the laminated structure in part of a mould in a sectional view.

[0097] FIG. 17 schematically shows part of a flow duct equipped with a full-body lining in a sectional perspective view.

[0098] FIG. 18 schematically shows part of a flow duct equipped with a lining strip in a sectional perspective view.

DETAILED DESCRIPTION OF INVENTION

[0099] A first embodiment of the present invention will now be described with reference to FIGS. 1 to 7. FIG. 1 shows the arrangement according to the invention. A bottom part of a mould 1 is used to support a number of layers 2, which are piled like a sandwich. The layers 2 are piled in a way that the three-dimensional shape (3D-shape) of the blade is achieved.

[0100] The piled layers may contain fibre-reinforced laminates and/or balsa wood and/or composite material and/or other useful materials. The layers are arranged and formed in a way that they are connected by an injected matrix material. Matrix material may contain resin, glue or any other kind of connecting material.

[0101] After the 3D-shape of the blade is finished by the stacked layers, a top mould is connected with the bottom mould. Thus a cavity is built by the two moulds, which contains the blade. Later resin is injected into the cavity to combine the layers of the blade. For this injection pressure or a technical vacuum is applied to the mould-system.

[0102] According to the invention at least one mould 1 contains at least one flow duct 3. The flow duct 3 is only partly integrated into the inner surface IS of the mould 1.

[0103] After the mould 1 is connected with at least another mould as described above the technical vacuum or the pressure is applied to the flow duct 3. Accordingly the flow duct 3 is used to inject a matrix material, like resin or a liquid polymer, into the closed mould-system.

[0104] Preferably each used flow duct 3 extends along the entire length of the mould 1.

[0105] Preferably some of the used flow ducts 3 are arranged to be used as an injection duct. This allows matrix material like resin to be injected into this flow ducts. Preferably some of the used flow ducts 3 are arranged to be used as a drain duct. Thus surplus matrix material is allowed to leave the mould system if needed.

[0106] The layers of the used fibre reinforced laminated material is laid out manually or automatically in a way that a desired composite structure is achieved.

[0107] FIG. 2 shows, in reference to FIG. 1, a preferred configuration of the invention. As described above resin is applied to a number of first flow ducts 3A, while a technical vacuum is applied to a number of second flow ducts 3B. The flow ducts 3A are part of a vacuum or a pressure distribution system 5. The flow ducts 3B are part of a matrix material or resin distribution system 4.

[0108] The distribution system 5 preferably contains various components like one or more vacuum units (not shown here). These vacuum units are used to generate the technical vacuum or they are used to generate low pressure. The distribution system 5 may also contain flexible hoses, pipes, couplings and seals to ensure that the distribution system is tight.

[0109] The distribution system 5 preferably is built up in a way that its reconfiguration is allowed. The reconfiguration may be done in dependency of certain system-requirements or in dependency of fault parts within the distribution system 5.

[0110] Preferably the flow ducts 3A, 3B are partly integrated in the mould 1. For example they are partly integrated tubes.

[0111] Preferably the technical vacuum or the low pressure is controlled by an applied open-loop control or by an applied closed-loop control. For this purpose the pressure (or pressure differences) is measured within the flow ducts 3A and/or within the flow ducts 3B. Preferably the pressure is controlled during the matrix material is injected.

[0112] Preferably the distribution system 5 is connected to one flow duct, while this flow duct is located substantially at the leading edge or at the trailing edge of the blade.

[0113] Preferably the distribution system 4 of the matrix material/resin contains a reservoir 6. Preferably the distribution system 4 contains one or more reservoirs 6, flexible hoses, pipes, couplings and/or seals. These components are arranged to ensure tight connections.

[0114] Preferably the matrix material is injected into the distribution system 4 by an applied pressure. Thus an increased pressure difference between the flow ducts 3A, where the matrix material is injected, and the flow ducts 3B, where surplus matrix material may leave the mould system is established. Thus an even higher flow rate is established.

[0115] Preferably the distribution system 4 and/or the distribution system 5 contain a flow control valve. This valve is arranged in a way that the amount and the flow of the matrix material and/or the amount of evacuated air are/is measured for control-purposes.

[0116] Preferably the distribution system 4 and/or the distribution system 5 contain a stop cock. The cock is used to control the flow of the injected matrix material and/or the flow of the evacuated air. The flow is stopped for example if a sufficient amount of matrix material was injected or it is stopped if an error (like a leaking hose) is detected.

[0117] FIG. 3 shows, in reference to FIG. 1 and to FIG. 2, the flow of the matrix material.

[0118] Whenever a blade, which contains components as described above, is manufactured the flow of the matrix material is of most importance. The matrix material needs to flow in a substantially free manner. Thus a uniform distribution of the matrix material is achieved in and between the used blade components.

[0119] Preferably the matrix material is injected via an inlet IN into the distribution system 4. Thus the matrix material is brought into a number of the flow ducts 3A.

[0120] The flow ducts 3 and their surface are constructed in a way that the matrix material is allowed to flow substantially free inside.

[0121] Furthermore the matrix material is injected into the piled layers 2 thus the blade-structure is permeated.

[0122] Surplus liquid polymer exits the blade-structure via a number of other flow ducts 3Bfor example those flow ducts, which are part of the distribution system 5 being used to apply the technical vacuum.

[0123] FIG. 4 shows a part of a blade BL, where surplus matrix material SMM extends from the surface SBL of the blade BL. This surplus matrix material SMM needs to be removed to optimize the surface SBL of the blade BL.

[0124] FIG. 5 shows in reference to FIG. 1 a flow duct 3, which contains a lining 50 according to the invention. The lining 50 is profiled and fits into the dedicated flow duct 3. Preferably the lining 50 does not extend above the flow duct 3 and the inner surface of the mould 1. So it does not influence the curvature of the fibre glass material laid down in the mould. When covered by fibre glass material, for example, the lining 50 forms an injection channel for matrix material like resin, as it forms a hollow profile.

[0125] During the blade-production-process resin is injected into the composite structure through this hollow profile and it is distributed along the extent of the lining 50. Thus a uniform distribution is obtained.

[0126] FIG. 6 shows in reference to FIG. 5 a part of the blade BL, where surplus matrix material SMM extends from the surface SBL of the blade BL, if a lining 50 is used according to the invention. Due to the cross-section of the lining 50 a predefined breaking edge BE is defined. This breaking edge BE allows removing of the surplus material SMM from the blade BL very easily.

[0127] FIG. 7 shows different cross sections of the lining, referring to FIG. 5 and to FIG. 6.

[0128] A second embodiment of the present invention will now be described with reference to FIGS. 8 to 12. The features which are described in conjunction with the first embodiment can be combined with the features which will be described in the second embodiment.

[0129] FIG. 8 schematically shows a wind turbine 11. The wind turbine 11 comprises a tower 12, a nacelle 13 and a hub 14. The nacelle 13 is located on top of the tower 12. The hub 14 comprises a number of wind turbine blades 15. The hub 14 is mounted to the nacelle 13. Moreover, the hub 14 is pivot-mounted such that it is able to rotate about a rotation axis 19. A generator 16 is located inside the nacelle 13. The wind turbine 11 is a direct drive wind turbine.

[0130] FIG. 9 shows a wind turbine blade 15 as it is usually used in a three-blade rotor. However, the present invention shall not be limited to blades for three-blade rotors. In fact, it may as well be implemented in other rotors, e.g. one-blade rotors or two-blade rotors.

[0131] The rotor blade 15 shown in FIG. 9 comprises a root 23 with a cylindrical profile and a tip 22. The tip 22 forms the outermost part of the blade 15. The cylindrical profile of the root 23 serves to fix the blade 15 to a bearing of the rotor hub 14. The rotor blade 15 further comprises a so-called shoulder 24 which is defined as the location of its maximum profile depth, i.e. the maximum chord length of the blade. Between the shoulder 24 and the tip 22 an airfoil portion 25 extends which has an aerodynamically shaped profile. Between the shoulder 24 and the cylindrical root 23, a transition portion 27 extends in which a transition takes place from the aerodynamic profile of the airfoil portion 25 to the cylindrical profile of the root 23.

[0132] A chord-wise cross section through the rotor blade's airfoil section 25 is shown in FIG. 10. Their aerodynamic profile shown in FIG. 10 comprises a convex suction side 33 and a less convex pressure side 35. The dash-dotted line extending from the blade's leading edge 29 to its trailing edge 21 shows the chord of the profile. Although the pressure side 35 comprises a convex section 37 and a concave section 39 in FIG. 10, it may also be implemented without a concave section at all as long as the suction side 33 is more convex than the pressure side 35.

[0133] The suction side 33 and the pressure side 35 in the airfoil portion 25 will also be referred to as the suction side and the pressure side of the rotor blade 15, respectively, although, strictly spoken, the cylindrical portion 23 of the blade 15 does not show a pressure or a suction side.

[0134] FIG. 11 schematically shows the resin flowing from the inlet channel integrated in the mould through the laminated structure in a sectional view. In FIG. 11 part of the mould 41 is shown in a sectional view. The mould 41 comprises an inner surface 46. A number of layers, for example fibre glass layers, forming a laminated structure 42 are placed onto the inner surface 46 of the mould 41. A vacuum bag 43 is placed onto the laminated structure 42. The vacuum bag 43 ensures that vacuum in the laminated structure 42 can be held.

[0135] An inlet channel 44 is integrated in the inner surface 46 of the mould 41. The inlet channel 44 is used to guide a matrix material, for example resin, to the laminated structure 42. The flow direction of the matrix material is indicated by arrows 45.

[0136] FIG. 12 schematically shows part of the mould covered with a laminated structure and a vacuum bag in a sectional view. In FIG. 12 the vacuum bag 43 comprises an outer side 47. On the outer side 47 of the vacuum bag 43 the pressure is atmospheric pressure p.sub.atm. The matrix material, for example resin, is injected in the inlet channel 44 with an inlet pressure p.sub.inlet. The resin can be injected with pressure higher than atmospheric pressure. Due to the flow resistance in the laminated structure 42, a pressure difference or pressure drop p across the structure will be present.

[0137] Generally it must be ensured that the vacuum bag 43 does not lump due to a resin or matrix material pressure at the inside surface 48 of the vacuum bag 43 that is higher than atmospheric pressure p.sub.atm. Consequently, the maximal inlet pressure of the matrix material p.sub.inlet that can be applied is: p.sub.inlet,max=p.sub.atm+P which is a value higher than atmospheric pressure p.sub.atm. This in turn ensures a higher inlet flow of matrix material or resin and therefore a shorter resin inlet time.

[0138] A third embodiment of the present invention will now be described with reference to FIGS. 8 to 10, 13 and 14. The features which are described in conjunction with the previously described embodiments can be combined with the features which will be described in the present embodiment. Regarding the description of FIGS. 8 to 10 it is here referred to the second embodiment.

[0139] FIG. 13 schematically shows an inventive closed mould arrangement in a sectional view. The mould comprises a lower mould part 51 and an upper mould part 52. The lower mould part 51 comprises an inner surface 61. The upper mould part 52 comprises an inner surface 62. In the inner surface 61 of the lower mould part 51 a number of flow ducts or inlet channels 57, 59 are integrated. In the inner surface 62 of the upper mould part 52 a number of flow ducts or inlet channels 58, 60 are integrated. The flow ducts or inlet channels 58, 59, 57, 60 comprise openings towards an inner cavity formed by the lower mould part 51 and the upper mould part 52.

[0140] Onto the inner surfaces 61, 62 of the mould parts 51, 52 a laminated structure 55 comprising a number of layers, for example fibre glass layers, are placed. Onto the laminated structure 55 a first mould core part 53 is placed close to the leading edge 29 of the blade which will be manufactured. Moreover, a second mould core part 54 is paced onto the laminated structure 55 close to the trailing edge 31 of the blade which will be manufactured. Between the first mould core part 53 and the second mould core part 54 a shear web or main beam 56 is placed. The shear web 56 connects the suction side 33 of the blade with the pressure side 35 of the blade to increase the stability of the blade.

[0141] The upper mould part 52 and/or the lower mould part 51 comprises a shear web portion or main beam portion 49 which is located close to the position of the shear web or main beam 56. A central flow duct 57 integrated in the lower mould part 51 is located at the shear web portion or main beam portion 49, preferably centred under the shear web or main beam 56. Moreover, a central flow duct 58 which is integrated in the upper mould part 52 is located at the shear web portion or main beam portion 49, preferably centred over the shear web 56.

[0142] The idea is to compensate for the permeability in the laminated structure by alternating the position of the inlet of matrix material, for example resin. The resin inlet is integrated in the mould as e.g. a channel. The permeability may be dependent on the thickness of the glass fibre structure or laminated structure 55, the density of the glass fibres in the glass fibre structure 55 or other flow parameters. The central flow ducts or inlet channels 57, 58 are centred under or over the main beam or shear web since the beam area typically comprises additional glass fibre material in order to ensure a sufficient transition between the blade shell and the beam 56.

[0143] FIG. 14 schematically shows a wind turbine rotor blade 15 in a sectional view along the plane defined by the blade's span and the blade's cord. FIG. 14 shows a preferred position for an inlet point or inlet opening 63 in the inlet channel. The inlet point 63 is preferably placed in the corresponding mould approximately at of the length from the root 23 to the tip 22 of the blade 15. This ensures that approximately half of the glass fibre material area is present on each side of the inlet point 63. This may in turn ensure a faster injection time, as the operation length from the inlet point 63 to an outlet is only A/2, whereas a normal operation length is from the trailing edge 31 to the leading edge 29 of the blade 15, which is a length of A.

[0144] A fourth embodiment of the present invention will now be described with reference to FIGS. 8 to 10 and 13 to 15. The features which are described in conjunction with the previously described embodiments can be combined with the features which will be described in the present embodiment. Regarding the description of FIGS. 8 to 10 and 13 to 15 it is here referred to the second embodiment.

[0145] An advantageous positioning of the flow duct or inlet channel in the mould depending on the thickness and/or permeability of the layers or laminated structure will now be described with reference to FIG. 15. FIG. 15 schematically shows part of a mould covered with a laminated structure in a sectional view.

[0146] In FIG. 15 a number of layers or a laminated structure 42 are/is placed onto the inner surface 46 of the mould 41. The laminated structure 42 comprises a first portion 42a and a second portion 42b. In the first portion 42a the laminated structure 42 has a thickness d.sub.1 and in the second portion 42b the laminated structure 42 has a thickness d.sub.2. The thickness d.sub.1 has a higher value than the thickness d.sub.2. In other words, the laminated structure of the first portion 42a is thicker than the laminated structure in the second portion 42b. The flow duct or inlet channel 44 is integrated in the inner surface 46 of the mould 41 at a position where the laminated structure 42 has a high thickness d, which is at the position of the first portion 42a of the laminated structure. This compensates for a lower permeability p.sub.1 in the first portion 42a of the laminated structure compared with a higher permeability p.sub.2 in the second portion 42b of the laminated structure.

[0147] Placing the flow ducts or inlet channels 44 at positions of high thickness d or low permeability p of the laminated structure 42 ensures a fast and uniform dispersion of the matrix material throughout the laminated structure 42.

[0148] A fifth embodiment of the present invention will now be described with reference to FIGS. 8 to 10, 13 and 16. The features which are described in conjunction with the previously described embodiments can be combined with the features which will be described in the present embodiment. Regarding the description of FIGS. 8 to 10 and 13 it is here referred to the second embodiment.

[0149] In the present embodiment of the invention the mould comprises more than one inlet channel. Resin may be injected in each of these inlets at different pressures, dependent on which structure and which permeability the resin is facing. This is schematically illustrated in FIG. 16.

[0150] FIG. 16 schematically shows a positioning of flow ducts depending on the permeability of the laminated structure in part of a mould in a sectional view. The laminated structure 42 comprises a first portion 42c with a first permeability, a second portion 42d with a second permeability, third portion 42e with a third permeability and a fourth portion 42f with a fourth permeability. The permeabilities differ from each other. A first inlet channel 44c is located adjacent to the first portion 42c. A second inlet channel 44d is located adjacent to the second portion 42d. A third inlet channel 44e is located adjacent to the third portion 42e. A fourth inlet channel 44f is located adjacent to the fourth portion 42f The different pressure drops caused by the different permeabilities are indicated by p.sub.1, p.sub.2, p.sub.3 and p.sub.4.

[0151] Matrix material, for example resin, is injected in each of these inlet channels 44c to 44f at different pressures, dependent on which structure and which permeability the matrix material is facing. For example, the injection pressure in the first inlet channel 44c may be p.sub.1=p.sub.atm+p.sub.1, the injection pressure in the second inlet channel 44d may be p.sub.2=p.sub.atm+p.sub.2, the injection pressure in the third inlet channel 44e may be p.sub.3=p.sub.atm+p.sub.3 and the injection pressure in the fourth inlet channel 44f may be p.sub.4=p.sub.atm+p.sub.4.

[0152] Even further the pressure inside the mould cavity i.e. the outside of the bag 43 may for various embodiments of the invention, be different than atmospheric pressure such as higher, which ensures that the resin inlet pressure may be increased even further, which in turn ensures a higher resin flow and faster resin inlet time.

[0153] FIG. 17 and FIG. 18 schematically show part of a flow duct equipped with a lining in a sectional perspective view. The flow ducts shown in FIGS. 17 and 18 can be applied to all previously described embodiments.

[0154] In FIG. 17 a flow duct 3 which is integrated in the inner surface of a mould 1 is shown. The flow duct 3 comprises an inner surface 20. The inner surface 20 is covered with a lining 8. Furthermore, the flow duct 3 is closed by the lining 8 towards the inner surface IS of the mould 1. The lining 8 comprises a number of openings or holes 10. The holes 10 are located in a portion of the lining 8 which closes the flow duct 3 towards the inner surface IS of the mould 1. This means, that the holes 10 provide openings between the flow duct 3 and the inner surface IS of the mould 1.

[0155] In FIG. 17 a full-body lining which fits into the lining channel or flow duct 3 is shown, whereas in FIG. 18 a lining strip 9 which is positioned substantially on top of the flow channel or flow duct 3 is shown. In FIG. 18 the flow duct 3 is only covered or closed by means of a lining strip 9 towards the inner surface IS of the mould 1. As the mould 1 may be made of a material to which the resin does not adhere, the lining 9 does not necessary cover the sides or the inner surface 20 of the flow duct 3. The lining strip 9 in FIG. 18 comprises a number of openings or holes 10. The holes 10 in FIG. 18 have the same properties as the holes 10 of FIG. 17.

[0156] For both the variants shown in FIGS. 17 and 18, the diameter of the holes may vary along the lining so as to regulate the flow of resin accordingly. Also the distance between the holes may vary for the same reasons.