Spar cap with tapering and serrated end section

Abstract

The present invention relates to a spar cap for a wind turbine blade and a method for manufacturing said spar cap. The spar cap comprises: a plurality of reinforcing fibre layers comprising unidirectionally oriented reinforcement fibres, wherein the plurality of reinforcing fibre layers are arranged such that the spar cap tapers in thickness towards a first longitudinal end, and a number of first fibre skin layers arranged on a first surface of the plurality of reinforcing fibre layers, and a number of second fibre skin layers arranged on a second surface of the plurality of reinforcing fibre layers, such that the plurality of reinforcing fibre layers are arranged between the number of first fibre skin layers and the number of second fibre skin layers. The number of first fibre skin layers and the number of second fibre skin layers extend beyond the plurality of reinforcing fibre layers towards the first longitudinal end of the spar cap, and the first longitudinal end of the spar cap is serrated along a transverse direction, forming a first serrated section.

Claims

1. A spar cap for a wind turbine blade, wherein the spar cap extends in a longitudinal direction between a first longitudinal end and a second longitudinal end and further in a transverse direction between a first side and a second side, and wherein the spar cap comprises: a plurality of reinforcing fibre layers comprising unidirectionally oriented reinforcement fibres, wherein the plurality of reinforcing fibre layers are arranged such that the spar cap tapers in thickness towards the first longitudinal end; and a number of first fibre skin layers arranged on a first surface of the plurality of reinforcing fibre layers, and a number of second fibre skin layers arranged on a second surface of the plurality of reinforcing fibre layers, such that the plurality of reinforcing fibre layers are arranged between the number of first fibre skin layers and the number of second fibre skin layers, wherein the number of first fibre skin layers and the number of second fibre skin layers extend beyond the plurality of reinforcing fibre layers towards the first longitudinal end of the spar cap, wherein the first longitudinal end of the spar cap is serrated along the transverse direction forming a first serrated section, and wherein the first serrated section comprises a plurality of serrations, wherein each of the serrations is formed by at least two of the reinforcing fibre layers, the number of first fibre skin layers, and the number of second fibre skin layers, such that each of the serrations is tapered towards the first longitudinal end by reducing a total number of the at least two of the reinforcing fibre layers, the number of first fibre skin layers, and the number of second fibre skin layers towards the first longitudinal end.

2. The spar cap according to claim 1, wherein the plurality of reinforcing fibre layers are arranged such that the spar cap tapers in thickness towards the second longitudinal end and wherein the number of first fibre skin layers and the number of second fibre skin layers additionally extend beyond the plurality of reinforcing fibre layers towards the second longitudinal end of the spar cap, and wherein the second longitudinal end of the spar cap is serrated along the transverse direction forming a second serrated section.

3. The spar cap according to claim 2, wherein the first serrated section is tapering towards the first longitudinal end of the spar cap and/or wherein the second serrated section is tapering towards the second longitudinal end of the spar cap.

4. The spar cap according to claim 1, wherein an outermost part of the first longitudinal end of the spar cap consists of one or more of the number of first fibre skin layers and one or more of the number of second fibre skin layers, and/or wherein an outermost part of the second longitudinal end of the spar cap consist of one or more of the number of first fibre skin layers and one or more of the number of second fibre skin layers.

5. The spar cap according to claim 1, wherein a part of the number of first fibre skin layers and a part of the number of second fibre skin layers extending beyond the plurality of reinforcing fibre layers towards the first longitudinal end of the spar cap is defined as a first extending section of the spar cap, wherein the first fibre skin layer and the second fibre skin layer are arranged in the first extending section such that at least part of an inner surface of one of the first fibre skin layers is contacted with at least part of an inner surface of one of the second fibre skin layers, wherein the inner surface is the surface turning toward the plurality of reinforcing fibre layers and/or wherein the part of the number of first fibre skin layers and the part of the number of second fibre skin layers extending beyond the plurality of reinforcing fibre layers towards the second longitudinal end of the spar cap is defined as a second extending section of the spar cap, wherein the first fibre skin layer and the second fibre skin layer are arranged in the second extending section such that at least part of an inner surface of one of the first fibre skin layers is contacted with at least part of an inner surface of one of the second fibre skin layers.

6. The spar cap according to claim 2, wherein the first serrated section is formed in the number of first fibre skin layers and in the number of second fibre skin layers only and/or wherein the second serrated section is formed in the number of first fibre skin layers and in the number of second fibre skin layers only or wherein the first serrated section is formed in the number of first fibre skin layers and in the number of second fibre skin layers and further extends into one or more of the plurality of reinforcing fibre layers, arranged most proximal to the first longitudinal end of the spar cap and/or wherein the second serrated section is formed in the number of first fibre skin layers and in the number of second fibre skin layers and further extends into one or more of the plurality of reinforcing fibre layers, arranged most proximal to the second longitudinal end of the spar cap.

7. The spar cap according to claim 2, wherein the first serrated section comprises a plurality of serrations, including a first serration having two first serration sides meeting in a first serration tip, wherein the angle between the two first serration sides are between 20-90 degrees, and wherein the first serrated section have a maximum thickness between 0.5 mm and 1 cm and/or wherein the second serrated section comprises a plurality of serrations, including a second serration having two second serration sides meeting in a second serration tip, wherein the angle between the two second serration sides are between 20-90 degrees, and wherein the second serrated section have a maximum thickness between 0.5 mm and 1 cm.

8. The spar cap according to claim 2, wherein an outermost part of the first serrated section of the spar cap consists of one or more of the number of first fibre skin layers and one or more of the number of second fibre skin layers, and/or wherein an outermost part of the second serrated section of the spar cap consists of one or more of the number of first fibre skin layers and one or more of the number of second fibre skin layers.

9. The spar cap according to claim 2, wherein the number of serrations along the first and/or the second serrated section comprises at least 5 serrations.

10. The spar cap according to claim 1, wherein the number of first fibre skin layers are arranged more distal to the first longitudinal end of the spar cap than the number of second fibre skin layers, whereby the number of first fibre skin layers and the number of second fibre skin layers are arranged such that the spar cap tapers in thickness towards the first longitudinal end of the spar cap and/or wherein the number of first fibre skin layers are arranged more distal to the second longitudinal end of the spar cap than the number of second fibre skin layers, whereby the number of first fibre skin layers and the number of second fibre skin layers are arranged such that the spar cap tapers in thickness towards the second longitudinal end of the spar cap.

11. The spar cap according to claim 1, wherein one or more of the number of first fibre skin layers and/or one or more of the number of second fibre skin layers are biaxial glass fibre layers or glass fibre mats.

12. The spar cap according to claim 1, wherein the unidirectionally oriented reinforcement fibres in the plurality of reinforcing fibre layers comprises carbon fibres and/or glass fibres and/or wherein the plurality of reinforcing fibre layers are composed of longitudinally extending precured fibre reinforced composite elements.

13. The spar cap according to claim 1, wherein the spar cap further comprises a plurality of interlayers arranged between the reinforcing fibre layers, wherein the interlayers are woven or non-woven fabrics each comprising or essentially consisting of fibres.

14. The spar cap according to claim 1, wherein the spar cap is embedded in a cured resin.

15. A wind turbine blade comprising the spar cap according to claim 1.

16. A method of manufacturing the spar cap according to claim 1, wherein the spar cap extends in a longitudinal direction between a first longitudinal end and a second longitudinal end and further in a transverse direction between a first side and a second side, wherein the method comprises the steps of: a) providing a spar cap mould, a plurality of reinforcing fibre layers comprising unidirectionally oriented reinforcement fibres, a number of first fibre skin layers and a number of second fibre skin layers; b) arranging the number of first fibre skin layers on a moulding surface of the spar cap mould; c) arranging the plurality of reinforcing fibre layers on top of the number of first fibre skin layers, such that a first surface of the plurality of reinforcing fibre layers are facing towards the number of first fibre skin layers, wherein the plurality of reinforcing fibre layers are arranged such that the spar cap tapers in thickness towards the first longitudinal end; d) arranging the number of second fibre skin layers on top of the plurality of reinforcing fibre layers, such that a second surface of the plurality of reinforcing fibre layers are facing towards the number of second fibre skin layers; and e) infusing the spar cap mould with a resin and curing the resin, wherein the number of first fibre skin layers and the number of second fibre skin layers are arranged such that they extend beyond the plurality of reinforcing fibre layers towards the first longitudinal end of the spar cap, and wherein the first longitudinal end of the spar cap is serrated along the transverse direction forming a first serrated section, and wherein the first serrated section comprises a plurality of serrations, wherein each of the serrations is formed by at least two of the reinforcing fibre layers, the number of first fibre skin layers, and the number of second fibre skin layers, such that each of the serrations is tapered towards the first longitudinal end by reducing a total number of the at least two of the reinforcing fibre layers, the number of first fibre skin layers, and the number of second fibre skin layers towards the first longitudinal end.

17. The method according to claim 16, wherein the plurality of reinforcing fibre layers are arranged such that the spar cap tapers in thickness towards the second longitudinal end and wherein the number of first fibre skin layers and the number of second fibre skin layers are arranged such that they additionally extend beyond the plurality of reinforcing fibre layers towards the second longitudinal end of the spar cap and wherein the second longitudinal end of the spar cap is serrated along the transverse direction forming a second serrated section.

18. The method according to claim 17, wherein the method comprises a step of cutting the first longitudinal end of the spar cap after the step of infusing the spar cap with resin and curing the resin to form the first serrated section and/or wherein the method comprises a step of cutting the second longitudinal end of the spar cap after the step of infusing the spar cap with resin and curing the resin to form the second serrated section.

19. A method of manufacturing a blade shell member for a wind turbine blade, the method comprising the steps of: a) providing a blade mould for the blade shell member; b) arranging a number of fibre-reinforcement layers on a blade moulding surface; c) providing the spar cap according to claim 1; d) arranging the spar cap on the number of fibre-reinforcement layers; e) infusing the mould cavity with resin; and f) curing the resin to form the blade shell member.

20. A method of manufacturing a wind turbine blade, comprising the steps of: manufacturing a pressure side shell half and a suction side shell half over substantially the entire length of the wind turbine blade, wherein each of the pressure side shell half and the suction side shell half is manufactured in accordance with the method of manufacturing a blade shell member of claim 19; and closing and joining the pressure side and suction side shell halves to obtain a closed shell.

21. A spar cap for a wind turbine blade, wherein the spar cap extends in a longitudinal direction between a first longitudinal end and a second longitudinal end and further in a transverse direction between a first side and a second side, and wherein the spar cap comprises: a plurality of reinforcing fibre layers comprising unidirectionally oriented reinforcement fibres, wherein the plurality of reinforcing fibre layers are arranged such that the spar cap tapers in thickness towards the first longitudinal end; and a number of first fibre skin layers arranged on a first surface of the plurality of reinforcing fibre layers, and a number of second fibre skin layers arranged on a second surface of the plurality of reinforcing fibre layers, such that the plurality of reinforcing fibre layers are arranged between the number of first fibre skin layers and the number of second fibre skin layers, wherein the number of first fibre skin layers and the number of second fibre skin layers extend beyond the plurality of reinforcing fibre layers towards the first longitudinal end of the spar cap, wherein the first longitudinal end of the spar cap is serrated along the transverse direction forming a first serrated section, and wherein the first serrated section is formed in the number of first fibre skin layers and in the number of second fibre skin layers and further extends into one or more of the plurality of reinforcing fibre layers arranged most proximal to the first longitudinal end of the spar cap.

22. The spar cap for a wind turbine blade according to claim 1, wherein the plurality of serrations include a first serration having two first serration sides meeting in a first serration tip, wherein an angle between the two first serration sides are between 20 and 90.

23. A spar cap for a wind turbine blade, wherein the spar cap extends in a longitudinal direction between a first longitudinal end and a second longitudinal end and further in a transverse direction between a first side and a second side, and wherein the spar cap comprises: a plurality of reinforcing fibre layers comprising unidirectionally oriented reinforcement fibres, wherein the plurality of reinforcing fibre layers are arranged such that the spar cap tapers in thickness towards the first longitudinal end; and a number of first fibre skin layers arranged on a first surface of the plurality of reinforcing fibre layers, and a number of second fibre skin layers arranged on a second surface of the plurality of reinforcing fibre layers, such that the plurality of reinforcing fibre layers are arranged between the number of first fibre skin layers and the number of second fibre skin layers, wherein the number of first fibre skin layers and the number of second fibre skin layers extend beyond the plurality of reinforcing fibre layers towards the first longitudinal end of the spar cap, wherein the first longitudinal end of the spar cap is serrated along the transverse direction forming a first serrated section, and wherein the number of first fibre skin layers are arranged more distal to the first longitudinal end of the spar cap than the number of second fibre skin layers, whereby the number of first fibre skin layers and the number of second fibre skin layers are arranged such that the spar cap and serrations of the first serrated section taper in thickness towards the first longitudinal end of the spar cap and/or wherein the number of first fibre skin layers are arranged more distal to the second longitudinal end of the spar cap than the number of second fibre skin layers, whereby the number of first fibre skin layers and the number of second fibre skin layers are arranged such that the spar cap and the serrations taper in thickness towards the second longitudinal end of the spar cap.

24. The spar cap according to claim 13, wherein the interlayer further comprises a binding agent or a thread for holding or stitching the fibres together, respectively.

Description

DETAILED DESCRIPTION OF THE INVENTION

(1) The invention is explained in detail below with reference to embodiments shown in the drawings, in which

(2) FIG. 1 is a schematic diagram illustrating a wind turbine,

(3) FIG. 2 is a schematic diagram illustrating a wind turbine blade and a spar cap structure arranged within the wind turbine blade,

(4) FIG. 3 is a schematic diagram illustrating embodiments of a spar cap according to the present invention, and

(5) FIG. 4 is a schematic diagram illustrating embodiments of a spar cap according to the present invention.

DETAILED DESCRIPTION

(6) FIG. 1 illustrates a conventional modern upwind wind turbine according to the so-called Danish concept with a tower 4, a nacelle 6 and a rotor with a substantially horizontal rotor shaft. The rotor includes a hub 8 and three blades 10 extending radially from the hub 8, each having a blade root 16 nearest the hub and a blade tip 14 farthest from the hub 8. The rotor has a radius denoted R.

(7) FIG. 2A shows a schematic view of a wind turbine blade 10. The wind turbine blade 10 has the shape of a conventional wind turbine blade and comprises a root region 30 closest to the hub, a profiled or an airfoil region 34 farthest away from the hub and a transition region 32 between the root region 30 and the airfoil region 34. The blade 10 comprises a leading edge 18 facing the direction of rotation of the blade 10, when the blade is mounted on the hub, and a trailing edge 20 facing the opposite direction of the leading edge 18.

(8) The airfoil region 34 (also called the profiled region) has an ideal or almost ideal blade shape with respect to generating lift, whereas the root region 30 due to structural considerations has a substantially circular or elliptical cross-section, which for instance makes it easier and safer to mount the blade 10 to the hub. The diameter (or the chord) of the root region 30 may be constant along the entire root area 30. The transition region 32 has a transitional profile gradually changing from the circular or elliptical shape of the root region 30 to the airfoil profile of the airfoil region 34. The chord length of the transition region 32 typically increases with increasing distance r from the hub. The airfoil region 34 has an airfoil profile with a chord extending between the leading edge 18 and the trailing edge 20 of the blade 10. The width of the chord decreases with increasing distance r from the hub.

(9) A shoulder 40 of the blade 10 is defined as the position, where the blade 10 has its largest chord length. The shoulder 40 is typically provided at the boundary between the transition region 32 and the airfoil region 34. FIG. 2A also illustrates the longitudinal extent L, length or longitudinal axis of the blade.

(10) It should be noted that the chords of different sections of the blade normally do not lie in a common plane, since the blade may be twisted and/or curved (i.e. pre-bent), thus providing the chord plane with a correspondingly twisted and/or curved course, this being most often the case in order to compensate for the local velocity of the blade being dependent on the radius from the hub.

(11) The blade is typically made from a pressure side shell part 36 and a suction side shell part 38 that are glued to each other along bond lines at the leading edge 18 and the trailing edge of the blade 20.

(12) FIG. 2B shows a schematic view of a cross section of the blade along the line I-I shown in FIG. 2A. As previously mentioned, the blade 10 comprises a pressure side shell part 36 and a suction side shell part 38. The pressure side shell part 36 and suction side shell part may be made from a plurality of fibre reinforcement layers (not shown), The pressure side shell part 36 comprises a first spar cap 41, also called a main laminate, which constitutes a load bearing part of the pressure side shell part 36. The first spar cap comprises a plurality of first reinforcing fibre layers 42 arranged on top of each other. The suction side shell part 38 comprises a second spar cap 45 comprises a plurality of second reinforcing fibre layers 46 arranged on top of each other. The pressure side shell part 36 may also comprise a first sandwich core material 43 typically made of balsawood or foamed polymer and sandwiched between the first plurality of fibre reinforcement layers. The first sandwich core material 43 is used to provide stiffness to the shell in order to ensure that the shell substantially maintains its aerodynamic profile during rotation of the blade. Similarly, the suction side shell part 38 may comprise a second sandwich core material 47.

(13) The first spar cap 41 of the pressure side shell part 36 and the second spar cap 45 of the suction side shell part 38 are connected via a first shear web 50 and a second shear web 55. The shear webs 50, 55 are in the shown embodiment shaped as substantially I-shaped webs. The first and second shear webs 50, 55 each comprises a shear web body and two web foot flanges. The shear web body comprises a sandwich core material 51, 56, such as balsawood or foamed polymer, covered by a number of skin layers 52, 57 made of a number of fibre layers. The blade shells 36, 38 may comprise further fibre reinforcement at the leading edge 18 and the trailing edge 16. Typically, the shell parts 36, 38 are bonded to each other via glue flanges.

(14) FIG. 3A is a schematic diagram illustrating a three-dimensional view of part of a spar cap 41, 45 according to an embodiment of the present invention. Only part of the spar cap is shown in FIG. 3A. The total length is not shown.

(15) The spar cap 41,45 is for a wind turbine blade 10 and extends in a longitudinal direction 100 between a first longitudinal end 101 and a second longitudinal end 102 and further in a transverse direction 103 between a first side 104 and a second side 105. Furthermore, the spar cap 41,45 have a thickness. As can be seen in FIG. 3A, the spar cap 41,45 tapers in thickness towards the first longitudinal end 101. This is because the spar cap comprises a plurality of reinforcing fibre layers 110 (not visible in FIG. 3A, see FIG. 3B-3D) arranged such that the spar cap 41,45 tapers in thickness towards the first longitudinal end 101. In FIG. 3A, the first longitudinal end 101 of the spar cap 41,45 is serrated along the transverse direction 103, forming a first serrated section 130 which is also tapering towards the first longitudinal end 101 of the spar cap 41,45.

(16) The first serrated section 130 comprises three serrations 132 each having two first serration sides 133 meeting in a first serration tip 134. The angle between the two first serration sides 133 are approximately 30 degrees. The serration tips 134 forms part of the first longitudinal end 101 of the spar cap 41,45. Even though the number of serrations 132 along the first serrated section 130 are three in FIG. 3A, this is only for illustrative purposes. Preferably, the first serrated section 130 comprises more than 10, such as between 10-200 serrations 132.

(17) As mentioned above, the spar cap 41,45 comprises a plurality of reinforcing fibre layers 110. The plurality of reinforcing fibre layers 110 comprises unidirectionally oriented reinforcement fibres. Furthermore, the spar cap comprises a number of first fibre skin layers 113 arranged on a first side of the plurality of reinforcing fibre layers 110, and a number of second fibre skin layers 114 arranged on a second side of the plurality of reinforcing fibre layers 110. This is not visible in FIG. 3A. However, FIGS. 3B and 3C are schematic diagrams illustrating two different embodiments of a cross-sectional view through the length of the spar cap 41,45 in FIG. 3A where the plurality of reinforcing fibre layers 110 and the first and second fibre skin layers 113, 114 can be seen.

(18) In FIG. 3B, three reinforcing fibre layers can be seen, including a second reinforcing fibre layer 110b most proximal to the second fibre skin layer 114 and two intermediate reinforcing fibre layers 110c arranged between a first reinforcing fibre layer 110a (not visible in FIG. 3) most proximal to the first fibre skin layer 113 and the second reinforcing fibre layer 110b. The spar cap 41, 45 tapers in thickness towards the first longitudinal end of the spar cap 101 because a first end 111b of the second reinforcing fibre layer 110b is arranged more proximal to the first longitudinal end of the spar cap 101 than a first end 111a of the first reinforcing fibre layer 110a (not visible) and because a first end 111c of each of the plurality of intermediate reinforcing fibre layers 110c are arranged with increasing proximity to the first longitudinal end of the spar cap 101 from the first reinforcing fibre layer 110a to the second reinforcing fibre layer 110b. The distance Furthermore, it can be seen that a first fibre skin layer 113 is arranged on a first side of the plurality of reinforcing fibre layers 110, and a second fibre skin layer 114 is arranged on a second side of the plurality of reinforcing fibre layers 110. The first fibre skin layer 113 and the second fibre skin layer 114 further extend beyond the plurality of reinforcing fibre layers 110 towards the first longitudinal end 101 of the spar cap 41,45. The first fibre skin layer 113 is arranged more distal to the first longitudinal end 101 of the spar cap 41,45 than the second fibre skin layer 114, whereby the number of first fibre skin layers 113 and the number of second fibre skin layers 114 are also arranged such that the spar cap 41,45 tapers in thickness towards the first longitudinal end 101 of the spar cap 41,45.

(19) In FIG. 3B, the first serrated section 130 is formed in the number of first fibre skin layers 113 and in the number of second fibre skin layers 114 only. Thus, the maximum thickness of the serrated section 130 in the embodiment of FIG. 3B is the thickness of two fibre skin layers 113, 114 and the minimum thickness is that of a single fibre skin layer 113, 114.

(20) In FIG. 3C, three reinforcing fibre layers can be seen, including a second reinforcing fibre layer 110b most proximal to the second fibre skin layer 114 and two intermediate reinforcing fibre layers 110c arranged between a first reinforcing fibre layer 110a (not visible in FIG. 3) most proximal to the first fibre skin layer 113 and the second reinforcing fibre layer 110b. The spar cap 41, 45 tapers in thickness towards the first longitudinal end of the spar cap 101 because a first end 111b of the second reinforcing fibre layer 110b is arranged more proximal to the first longitudinal end of the spar cap 101 than a first end 111a of the first reinforcing fibre layer 110a (not visible) and because a first end 111c of each of the plurality of intermediate reinforcing fibre layers 110c are arranged with increasing proximity to the first longitudinal end of the spar cap 101 from the first reinforcing fibre layer 110a to the second reinforcing fibre layer 110b. Furthermore, it can be seen that two first fibre skin layers 113 are arranged on a first side of the plurality of reinforcing fibre layers 110, and one second fibre skin layer 114 is arranged on a second side of the plurality of reinforcing fibre layers 110. The two first fibre skin layers 113 and the second fibre skin layer 114 further extend beyond the plurality of reinforcing fibre layers 110 towards the first longitudinal end 101 of the spar cap 41,45. The two first fibre skin layers 113 are arranged more distal to the first longitudinal end 101 of the spar cap 41,45 than the second fibre skin layer 114. Furthermore, one of the first fibre skin layers 113 are arranged more distal to the first longitudinal end 101 of the spar cap 41,45 than the other first fibre skin layer 113. Thus, the number of first fibre skin layers 113 and the number of second fibre skin layers 114 are also arranged such that the spar cap 41,45 tapers in thickness towards the first longitudinal end 101 of the spar cap 41,45.

(21) In FIG. 3C, the first serrated section 130 is formed in the two first fibre skin layers 113 and in the second fibre skin layer 114 and further extends into two of the reinforcing fibre layers, namely the second reinforcing fibre layer 110b and the intermediate reinforcing fibre layer 110c most proximal to the second reinforcing fibre layer 110b. Thus, the maximum thickness of the serrated section 130 in the embodiment of FIG. 3B is the thickness of three fibre skin layers 113, 114 plus two fibre reinforcing layers 110 and at least one interlayer 122 arranged between the fibre reinforcing layers 110. Again, the minimum thickness is that of a single fibre skin layer 113, 114. However, in other embodiments, the minimum thickness could be more than the thickness of one fibre skin layer. In such cases, the first longitudinal end would be formed by two fibre skin layers arranged such that their first end are not displaced relative to each other.

(22) The outermost part of the first longitudinal end of the spar cap includes the tip of the serrations in the serrated section.

(23) In FIGS. 3B and 3C, a first end 116 of the second fibre skin layer 114 forms the first longitudinal end 101 of the spar cap 41,45. In both embodiments, an outermost part of the serrated section i.e., the serration tips 134, of the spar cap consist of the second fibre skin layer 114a. However, in other embodiments, the outermost part of the serrated section 134 may consist of one or more of the number of first fibre skin layers 113 and one or more of the number of second fibre skin layers 114, preferably only one or two fibre skin layers 113, 114. The outmost part of the serrated section 134 will never comprise one or more of the plurality of reinforcing fibre layers 110.

(24) FIG. 3D is a schematic diagram illustrating a cross-sectional view through the width of an embodiment of a spar cap 41,45 according to the present invention. The width is defined between the first and second side 104, 105 of the spar cap 41,45.

(25) In the embodiment shown in FIG. 3D, the spar cap 41,45 comprises three stacked reinforcing fibre layers. Furthermore, the spar cap comprises a first fibre skin layer 113 arranged on a first surface of the three fibre reinforcing layers 110a, 110b, 110c and a second fibre skin layer 114 is arranged on a second surface of the three fibre reinforcing layers 110a, 110b, 110c. Furthermore, the spar cap 41,45 comprises three interlayers 122 arranged between the three reinforcing fibre layers 110.

(26) The three reinforcing fibre layers includes a first reinforcing fibre layer 110a arranged most proximal to the first fibre skin layer 113, a second reinforcing fibre layer 110b arranged most proximal to the second fibre skin layer 114 and an intermediate reinforcing fibre layers 110c arranged between a first reinforcing fibre layer 110a and the second reinforcing fibre layer 110b. The three fibre reinforcing layers 110a, 110b, 110c are each composed of three longitudinally extending precured fibre reinforced composite elements 120, such as pultruded planks. Thus, the precured fibre reinforced composite elements 120 are arranged in an array comprising three fibre reinforced element stacks 121 arranged adjacent to each other. Each fibre reinforced element stack 121 comprising three precured fibre reinforced composite elements 120 arranged on top of each other.

(27) The spar cap 41,45 is embedded in a cured resin (not visible in FIG. 3D) for adhering the reinforcing fibre layers 110 as well as the first fibre skin layer 113 and second fibre skin layer 114 to each other. The interlayers 122 are woven or non-woven fabrics each comprising or essentially consisting of fibres configured for promoting resin flow between the reinforcing fibre layers 110.

(28) FIG. 4A is a schematic diagram illustrating a top view of a spar cap 41,45 according to an embodiment of the present invention and FIG. 4B is a schematic diagram illustrating a side view of the spar cap 41,45 in FIG. 4A.

(29) The spar cap 41,45 illustrated in FIGS. 4A and 4B is for a wind turbine blade 10 and extends in a longitudinal direction 100 between a first longitudinal end 101 and a second longitudinal end 102 and further in a transverse direction 103 between a first side 104 and a second side 105 as can be seen in FIG. 4A. Furthermore, the spar cap 41,45 have a thickness. As can be seen in FIG. 4B, the spar cap 41,45 tapers in thickness towards the first longitudinal end 101 and towards the second longitudinal end 102. This is because the plurality of reinforcing fibre layers 110 are arranged such that the spar cap 41,45 tapers in thickness towards the first longitudinal end 101 and the second longitudinal end 102. Furthermore, as can be seen in FIG. 4A, the first longitudinal end 101 and the second longitudinal end 102 of the spar cap 41,45 are serrated along the transverse direction 103, forming a first serrated section 130 and a second serrated section 131.

(30) In FIG. 4A, both the first and the second serrated section 130, 131 comprises six serrations 132 each having two first serration sides 133 meeting in a first serration tip 134. The angle between the two first serration sides are approximately 30 degrees. The serration tips 134 forms part of the first longitudinal end 101 of the spar cap 41,45.

(31) The spar cap 41,45 comprises a plurality of reinforcing fibre layers 110 comprising unidirectionally oriented reinforcement fibres, a number of first fibre skin layers 113 arranged on a first side of the plurality of reinforcing fibre layers 110, and a number of second fibre skin layers 114 arranged on a second side of the plurality of reinforcing fibre layers 110. Only the first fibre skin layer 113 can be seen in FIG. 4A. However, FIG. 4D is a schematic diagrams illustrating an embodiment of a cross-sectional view through the length of the spar cap 41,45 in FIGS. 4A and 4B, where the arrangement of the plurality of reinforcing fibre layers 110 and the first and second fibre skin layers 113, 114 can be seen.

(32) In FIG. 4D, twenty-one reinforcing fibre layers 110 comprising unidirectionally oriented reinforcement fibres can be seen. The twenty-one reinforcing fibre layers 110 are stacked and includes a first reinforcing fibre layer 110a most proximal to the number of first fibre skin layers 113, a second reinforcing fibre layer 110b most proximal to the number of second fibre skin layers and nineteen intermediate reinforcing fibre layers 110c arranged between the first and second reinforcing fibre layer 110a, 110b.

(33) Furthermore, it can be seen that two first fibre skin layers 113 are arranged on a first side of the plurality of reinforcing fibre layers 110, and one second fibre skin layer is arranged on a second side of the plurality of reinforcing fibre layers 110. The first fibre skin layer 113 and the second fibre skin layer 114 further extend beyond the plurality of reinforcing fibre layers 110 towards the first longitudinal end 101 of the spar cap 41,45.

(34) The spar cap 41,45 tapers in thickness towards the first longitudinal end 101 of the spar cap 41,45 because a first end 111b of the second reinforcing fibre layer 110b is arranged more proximal to the first longitudinal end 101 of the spar cap 41,45 than a first end 111a of the first reinforcing fibre layer 110a and because a first end 111c of each of the plurality of intermediate reinforcing fibre layers 110c are arranged with decreasing proximity to the first longitudinal end 101 of the spar cap 41,45 from the second reinforcing fibre layer 110b to the first reinforcing fibre layer 110a. This is achieved by the plurality of reinforcing fibre layers 110a, 110b, 110c having varying lengths, with the first reinforcing fibre layer 110a having the shortest length and the second reinforcing fibre layer having the greatest length 110b. Furthermore, there is a distance between a first end 111a, 111b, 111c of adjacent reinforcing fibre layers 110a, 110b, 110c.

(35) Furthermore, two first fibre skin layer 113 are arranged more distal to the first longitudinal end 101 of the spar cap 41,45 than the second fibre skin layer 114 and one of the first fibre skin layers 113 are arranged more distal to the first longitudinal end 101 of the spar cap 41,45 than the other first fibre skin layer 113. Thus, the number of first fibre skin layers 113 and the number of second fibre skin layers 114 are also arranged such that the spar cap 41,45 tapers in thickness towards the first longitudinal end 101 of the spar cap 41,45.

(36) In FIG. 4D, it can be seen that the first serrated section 130 is formed in the two first fibre skin layers 113 and in the number of second fibre skin layers 114 only. Thus, the first serrated section 130 tapers towards the first longitudinal end 101 due to the arrangement of the first and second fibre skin layers 113, 114. Thus, the maximum thickness of the first serrated section 130 in the embodiment of FIG. 4D is the thickness of three fibre skin layers 113, 114 and the minimum thickness is that of a single fibre skin layer 113, 114.

(37) In FIG. 4, a first end 116 of the second fibre skin layer 114 forms the first longitudinal end 101 of the spar cap 41,45. The first end 116 of the second fibre skin layer 114 also forms the serration tip 134 of each of the serrations 132 in the first serrated part 130.

(38) FIG. 4C is a schematic diagram illustrating a close-up view of the second serrated section 131 in FIG. 4B. Due to the tapering configuration of the spar cap 41,45 towards the second longitudinal end 102 and the second serrated section 131, the second longitudinal end 102 of the spar cap 41,45 is pliable and can easily conform to a surface with inconsistencies. The same applies for the first longitudinal end of the spar cap 41,45 illustrated in FIG. 4C.

(39) The spar cap 41,45 according to the present invention, is a spar cap 41,45 made offline, i.e. a premanufactured spar cap 41,45 made outside the wind turbine blade mould. As illustrated in FIGS. 3 and 4, the spar cap 41,45 is manufactured with at least a first serrated section 130 at the first longitudinal end 101 of the spar cap 41,45. This is to allow the first longitudinal end 101 of the spar cap 41,45 to easily conform to the fibre reinforcement material laid up in the turbine blade shell mould before arranging the spar cap 41,45 therein, independently of panel stiffness curve, local irregularities and geometry deviations of the fibre reinforcement material laid up in the turbine blade shell mould. However, in preferred embodiments and as illustrated in FIGS. 4A and 4B, the spar cap 41,45 comprises a serrated section at each longitudinal end 101 of the spar cap 41,45. A spar cap 41,45 comprising two serrated sections 130, 131 will even more easily conform to the fibre reinforcement material laid up in the turbine blade shell mould than a spar cap 41,45 with only a first serrated section.

(40) It should be emphasized that the dimensions in the schematic illustrations of FIGS. 3 and 4 are exaggerated for illustrative purposes.

LIST OF REFERENCE NUMERALS

(41) 4 tower 6 nacelle 8 hub wind turbine blade 14 blade tip 16 blade root 18 leading edge 20 trailing edge 30 root region 32 transition region 34 airfoil region 36 pressure side shell part 38 suction side shell part 39 fibre reinforcement layers 40 shoulder 41 first spar cap 42 first reinforcing fibre layers 43 first sandwich core material 45 second spar cap 46 second reinforcing fibre layers 47 second sandwich core material 50 first shear web 51 sandwich core material of first shear web 52 skin layer of first shear web 55 second shear web 56 sandwich core material of second shear web 57 skin layers of second shear web 100 longitudinal direction 101 first longitudinal end of spar cap 102 second longitudinal end of spar cap 103 transverse direction 104 first side of spar cap 105 second side of spar cap 106 thickness direction 110 reinforcing fibre layer 110a first reinforcing fibre layer 110b second reinforcing fibre layer 110c intermediate reinforcing fibre layer 111a first end of first reinforcing fibre layer 111b first end of second reinforcing fibre layer 111c first end of intermediate reinforcing fibre layer 112a second end of first reinforcing fibre layer 112b second end of second reinforcing fibre layer 112c second end of intermediate reinforcing fibre layer 113 first fibre skin layer 114 second fibre skin layer 114a primary second fibre skin layer 115 first end of first fibre skin layer 116 first end of second fibre skin layer 116a first end of primary second fibre skin layer 117 second end of first fibre skin layer 118 second end of second fibre skin layer 118a second end of primary second fibre skin layer 120 precured fibre reinforced element e.g., pultruded plank 121 precured fibre reinforced element stack 122 interlayer 130 first serrated section 131 second serrated section 132 serration 133 serration side 134 serration tip