HEATING ELEMENT FOR AN OUTER SURFACE OF A WIND TURBINE ROTOR BLADE

Abstract

A heating element for an outer surface of a wind turbine rotor blade, wherein the heating element has a length and a width. The heating element includes a carbon fiber layer having a plurality of slots subdividing the carbon fiber layer into consecutive band sections defining a current path between a first connecting portion and a second connecting portion. The first connecting portion is adapted to be connected to a first power supply line and the second connecting portion is adapted to be connected to a second power supply line. The current path has a length of at least twice the length of the heating element.

Claims

1. A heating element for an outer surface of a wind turbine rotor blade, the heating element having a length and a width and comprising: a first connecting portion and a second connecting portion; a carbon fiber layer having a plurality of slots subdividing said carbon fiber layer into consecutive band sections conjointly defining a current path between said first connecting portion and said second connecting portion; said current path having a length of at least twice the length of said heating element; and, said first connecting portion being configured to be connected to a first power supply line and the second connecting portion being configured to be connected to a second power supply line.

2. The heating element of claim 1, wherein said first and second connecting portions are located on respective opposite ends of said carbon fiber layer.

3. The heating element of claim 1, said heating element further comprising an electrically insulating carrier layer carrying said carbon fiber layer.

4. The heating element of claim 3, wherein said electrically insulating carrier layer carries said carbon fiber layer in accordance with at least one of the following: i) said electrically insulating carrier layer extends over the full length of the heating element; and, ii) said electrically insulating carrier layer bridges said slots.

5. The heating element of claim 1, wherein at least one of the following applies: i) said slots have a width of at least 1 mm; ii) said band sections have a width of at least 20 mm; iii) a width of the band sections changes along said current path; and, iv) a width of the slots changes along said current path.

6. The heating element of claim 1, wherein said slots are arranged in parallel and along the length-direction or along the width-direction of the heating element.

7. The heating element of claim 1, wherein said carbon fiber layer defines an edge and at least one of said slots begins at said edge of said carbon fiber layer.

8. A heating element for an outer surface of a wind turbine rotor blade, the heating element having a length and a width and comprising: a first connecting portion and a second connecting portion; a carbon fiber layer having a plurality of slots subdividing said carbon fiber layer into consecutive band sections conjointly defining a current path between said first connecting portion and said second connecting portion; said current path having a length of at least twice the length of said heating element; and, said first connecting portion being configured to be connected to a first power supply line and the second connecting portion being configured to be connected to a second power supply line, wherein at least one of said slots has a widened end section.

9. The heating element of claim 1, wherein a central band section of said current path has a width less than at least one of the following: i) a width of the band section near said first connecting portion; and, ii) a width of the band section near said second connecting portion.

10. The heating element of claim 1, wherein said carbon fiber layer covers at least 70% of a surface area covered by said heating element.

11. A heating element for an outer surface of a wind turbine rotor blade, the heating element having a length and a width and comprising: a first connecting portion and a second connecting portion; a carbon fiber layer having a plurality of slots subdividing said carbon fiber layer into consecutive band sections conjointly defining a current path between said first connecting portion and said second connecting portion; said current path having a length of at least twice the length of said heating element; and, said first connecting portion being configured to be connected to a first power supply line and the second connecting portion being configured to be connected to a second power supply line, wherein said carbon fiber layer comprises a fleece including carbon fibers arranged in various, random orientations.

12. The heating element of claim 1, wherein said carbon fiber layer comprises a fabric including carbon fibers arranged in at least one of the following ways: i) in at least two different directions; and, ii) in at least three different directions.

13. A wind turbine rotor blade comprising: a rotor blade body having a pressure side and a suction side; a heating element having a length and a width and including: a first connecting portion and a second connecting portion; said heating element being fastened to the wind turbine rotor blade so as to cause said first connecting portion to be arranged on said suction side and said second connecting portion to be arranged on said pressure side; a carbon fiber layer having a plurality of slots subdividing said carbon fiber layer into consecutive band sections conjointly defining a current path between said first connecting portion and said second connecting portion; said current path having a length of at least twice the length of said heating element; and, said first connecting portion being configured to be connected to a first power supply line and said second connecting portion being configured to be connected to a second power supply line.

14. A method of making a heating element for an outer surface of a wind turbine rotor blade, the method comprising the steps of: providing a carbon fiber layer having a length and a width; forming a plurality of slots within the carbon fiber layer thereby subdividing the carbon fiber layer into consecutive band sections defining a current path between a first connecting portion and a second connecting portion, wherein the current path has a length of at least twice the length of the carbon fiber layer; and, configuring the first connecting portion of the carbon fiber layer and the second connecting portion of the carbon fiber layer so as to be connectable to a first power supply line and so as to be connectable to a second power supply line, respectively.

15. The method of claim 14, comprising the following additional steps: providing an electrically insulating carrier layer; and, connecting the carbon fiber layer to the carrier layer.

16. A method of making a wind turbine rotor blade with a heating element, the method comprising the steps of: providing a carbon fiber layer having a length and a width; forming a plurality of slots within the carbon fiber layer thereby subdividing the carbon fiber layer into consecutive band sections defining a current path between a first connecting portion and a second connecting portion, wherein the current path has a length of at least twice the length of the carbon fiber layer; configuring the first connecting portion of the carbon fiber layer and the second connecting portion of the carbon fiber layer so as to be connectable to a first power supply line and so as to be connectable to a second power supply line, respectively; providing an electrically insulating carrier layer; and, fastening the carbon fiber layer to an outer surface of the wind turbine rotor blade, wherein the carrier layer is fastened to the outer surface or is removed after the carbon fiber layer has been fastened to the outer surface.

17. A heating element assembly for an outer surface of a wind turbine rotor blade, the heating element assembly comprising: a first power supply line and a second power supply line; a heating element having a length and a width and including: a first connecting portion and a second connecting portion; a carbon fiber layer having a plurality of elongated openings subdividing said carbon fiber layer into consecutive band sections conjointly defining a zig-zag current path between said first and second connecting portions; said first connecting portion being connected to said first power supply line and said second connecting portion being connected to said second power supply line; and, said current path having a length of at least twice the length of said heating element.

18. The heating element assembly of claim 17, wherein at least one of said elongated openings has a widening formed at the inner end of said at least one elongated opening to reduce current density in said current path next to the end of said at least one elongated opening and so prevent local overheating.

19. The heating element assembly of claim 18, wherein said widening is formed to have a keyhole configuration.

Description

BRIEF DESCRIPTION OF DRAWING

[0053] The invention will now be described with reference to the drawing wherein:

[0054] FIG. 1 shows a heating element fastened to a wind turbine rotor blade in a schematic view.

DETAILED DESCRIPTION

[0055] FIG. 1 shows a section of a wind turbine rotor blade 10 having a leading edge 12 facing the viewer. The wind turbine rotor blade 10 includes a suction side 14 shown above the leading edge 12, and a pressure side 16 shown below the leading edge 12.

[0056] A heating element 18 is fastened to an outer surface of the wind turbine rotor blade 10. The heating element 18 has a rectangular shape with two first opposing edges 20a, 20b arranged substantially parallel to the leading edge 12, and two second opposing edges 22a, 22b arranged substantially perpendicular to the leading edge 12. Each of the two opposing edges 20a, 20b defines a width of the heating element 18, and each of the two second opposing edges 22a, 22b defines a length of the heating element 18.

[0057] The heating element 18 includes a carbon fiber layer 24 which is subdivided by a plurality of slots 26a to 26j into consecutive band sections 28a to 28k. These band sections 28a to 28k each extend essentially parallel to the leading edge 12 and over the entire width of the carbon fiber layer 24, essentially corresponding to the entire length of the heating element 18. Each band section 28a to 28k has a width indicated in FIG. 1 by a double arrow next to the reference numerals 28a to 28k.

[0058] Each of the slots 26a to 26j begins from one of the opposing edges 22a or 22b, respectively, and ends in a circular, widened section 30 as is indicated in FIG. 1 for slot 26a only.

[0059] The carbon fiber layer 24 includes a first connecting portion 32a and a second connecting portion 32b. The first connecting portion 32a is connected to a first power supply line 34a, the second connecting portion 32b is connected to a second power supply line 34b. The first power supply line 34a is connected to a first down conductor 36a arranged on the suction side 14, running along the wind turbine rotor blade length. The second power supply line 34b is connected to a first down conductor 36b arranged on the pressure side 16, also running along the wind turbine rotor blade length.

[0060] The heating element 18 includes an electrically insulating carrier layer 38 covering the entire surface area of the heating element 18. The electrically insulating carrier layer 38 extends continuously between the four opposing edges 20a, 20b, 22a, 22b and bridges the slots 26a to 26j.

[0061] A current path is provided running from the first connecting portion 32a through each of the band sections 28a to 28k to the second connecting portion 32b. As there are eleven band sections 28a to 28k in the example shown (any number of band sections can be realized, for example at least three band sections formed by two slots), the length of the current path is about eleven times the width of the heating element 18, which is much longer than twice the length of the heating element 18. The band sections 28e and 28f form a central part of the current path and have a smaller width than the band sections 28a, 28k near the connecting portions 32a, 32b.

[0062] FIG. 1 shows a section of a rotor blade with one heating element 18 only. One may arrange various heating elements 18 side-by-side along the leading edge 12 of the wind turbine rotor blade to cover parts of the surface area or the entire surface area of the wind turbine rotor blade that requires heating. The heating elements 18 will then be connected to the down conductors 36a, 36b in parallel.

[0063] It is understood that the foregoing description is that of the preferred embodiments of the invention and that various changes and modifications may be made thereto without departing from the spirit and scope of the invention as defined in the appended claims.

LIST OF REFERENCE NUMERALS

[0064] 10 wind turbine rotor blade [0065] 12 leading edge [0066] 14 suction side [0067] 16 pressure side [0068] 18 heating element [0069] 20a, 20b first opposing edges [0070] 22a, 22b second opposing edges [0071] 24 carbon fiber layer [0072] 26a-26j slots [0073] 28a-28k band sections [0074] 30 widened end section [0075] 32a first connecting portion [0076] 32b second connecting portion [0077] 34a first power supply line [0078] 34b second power supply line [0079] 36a first down conductor [0080] 36b second down conductor [0081] 38 carrier layer