OPTIMIZED SPAR CAP STRUCTURE FOR WIND TURBINE BLADE

Abstract

The present disclosure relates to a spar cap (10) for a wind turbine blade (1000) comprising: a plurality of spar cap layers (20) and a first interlayer (30) arranged between the first spar cap layer (20a) and the second spar cap layer (20b) and comprising: a number of first interlayer areas (31), including a first primary interlayer area (31a), comprising a first number of interlayer sheets (33) comprising a first plurality of fibres (35); and a number of second interlayer areas (32), including a second primary interlayer area (32a), comprising a second number of interlayer sheets (34) comprising a second plurality of fibres (36), wherein the first number of interlayer sheets (33) is of a different characteristic than the second number of interlayer sheets (34).

Claims

1. A spar cap (10) for a wind turbine blade (1000) comprising: a plurality of spar cap layers (20) including a first spar cap layer (20a) comprising a first number of pre-cured fibre-reinforced elements (21), including a first primary pre-cured fibre-reinforced element (21a); and a second spar cap layer (20b) comprising a second number of pre-cured fibre-reinforced elements (22), including a second primary pre-cured fibre-reinforced element (22a); wherein each of the first and second number of pre-cured fibre reinforced elements (21, 22) have a length (L), a width (W) and a thickness (T), a first interlayer (30) arranged between the first spar cap layer (20a) and the second spar cap layer (20b) and comprising: a number of first interlayer areas (31), including a first primary interlayer area (31a), comprising a first number of interlayer sheets (33) comprising a first plurality of fibres (35); a number of second interlayer areas (32), including a second primary interlayer area (32a), comprising a second number of interlayer sheets (34) comprising a second plurality of fibres (36); wherein the first number of interlayer sheets (33) is of a different characteristic than the second number of interlayer sheets (34).

2. A spar cap according to claim 1, wherein the different characteristic is fibre type and/or fibre density and/or fibre ratio.

3. A spar cap according to claim 1, wherein the first spar cap layer (20a), the second spar cap layer (20b) and the first interlayer (30) each have a length (La, Lb, Lc), a width (Wa, Wb, Wc) and a thickness (Ta, Tb, Tc), wherein the width (Wc) and length (Lc) of the first interlayer is substantially the same as the width (Wa, Wb) and length (La, Lb), respectively, of the first and/or second spar cap layer.

4. A spar cap according to any of the preceding claims, wherein the first spar cap layer (20a), the second spar cap layer (20b) and the first interlayer (30) each have a first surface area (20aa, 20ba, 30a) and an opposite second surface area (20ab, 20bb, 30b), wherein the first surface area (20aa, 20ba, 30a) of the first spar cap layer (20a), the second spar cap layer (20b) and the first interlayer (30) is defined by the width and length of the first spar cap layer (20a), the second spar cap layer (20b) or the first interlayer (30), respectively, and wherein the first surface area (30a) of the first interlayer (30) is in contact with the second surface area (20ab) of the first spar cap layer (20a) and the second surface area (30b) of the first interlayer (30) is in contact with the first surface area (20ba) of the second spar cap layer (20b).

5. A spar cap according to any of the preceding claims, wherein the first spar cap layer (20) further comprises a first secondary pre-cured fibre-reinforced element (21b) arranged adjacent to the first primary pre-cured fibre reinforced element (21a), such that a first side of the first primary pre-cured fibre-reinforced element (21a) defined by the thickness and length of the first primary pre-cured fibre-reinforced element (21a), is adjacent to a second side of the first secondary pre-cured fibre-reinforced element (21b), defined by the thickness and length of the first secondary pre-cured fibre-reinforced element (21b).

6. A spar cap according to any of the preceding claims, wherein the first primary interlayer area (31a) extends along a first part of the length of the first interlayer (30) and wherein the second primary interlayer area (32a) extends along a second part of the length of the first interlayer (30).

7. A spar cap according to any of the preceding claims, wherein the first primary interlayer area (31a) extends along a first part of the width of the first interlayer (30) and wherein the second primary interlayer area (32a) extends along a second part of the width of the first interlayer (30).

8. A spar cap according to any of the preceding claims, wherein the second primary interlayer area (32a) is surrounded by the first primary interlayer area (31a).

9. A spar cap according to any of the preceding claims, wherein the first primary interlayer area (31a) forms at least part of a perimeter of the first interlayer (30).

10. (canceled)

11. (canceled)

12. A spar cap according to any claim 1, wherein the first interlayer (30) comprises a plurality of second interlayer areas (32), including the second primary interlayer area (32a).

13. A spar cap according to claim 12, wherein the first plurality of interlayer areas (31) and the second plurality of interlayer areas (32) each extends along part of the length of the first interlayer (30), and wherein the first plurality of interlayer areas (31) and the second plurality of interlayer areas (32) are alternating along the length of the first interlayer (30).

14. A spar cap according to any of claim 12 or 13, wherein the first plurality of interlayer areas (31) and the second plurality of interlayer areas (32) each extends along part of the width of the first interlayer (30), and wherein the first plurality of interlayer areas (31) and the second plurality of interlayer areas (32) are alternating along the width of the first interlayer (30).

15. A spar cap according to any of the preceding claims, wherein first number of interlayer sheets and the second number of interlayer sheets are arranged adjacent to each other, such that adjacent edges of the interlayer sheets are contacted with each other or wherein the first number of interlayer sheets and the second number of interlayer sheets overlap each other in areas where they meet.

16. A spar cap according to any of the preceding claims, wherein the first plurality of fibres (35) comprises polymeric filaments, such as polyester filaments, preferably thermoplastic polyester filaments or polypropylene filaments or polyethylene filaments.

17. A spar cap according to any of the preceding claims, wherein the second plurality of fibres (36) comprises glass fibres and/or carbon fibres.

18. (canceled)

19. A spar cap according to any of the preceding claims, wherein the first and/or second number of interlayer sheets (33, 34) are veils comprising randomly oriented fibres.

20. A spar cap according to any of the preceding claims, wherein the first and/or second number of interlayer sheets (33, 34) are nets, comprising woven fibres.

21. (canceled)

22. A spar cap according to any of the preceding claims, wherein the first number of interlayer sheets (33) are polyester veils and the second number of interlayer sheets (34) are bidirectional glass-fibre fabrics.

23. A spar cap according to any of the preceding claims, wherein each of the plurality of pre-cured fibre reinforced elements (21, 22) are pultruded carbon fibre reinforced plastic planks.

24. (canceled)

25. A wind turbine blade comprising a spar cap according to claim 1.

Description

DETAILED DESCRIPTION

[0079] Embodiments of the disclosure will be described in more detail in the following with regards to the accompanying figures. The figures show one way of implementing the present disclosure and are not to be construed as being limiting to other possible embodiments falling within the scope of the attached claim set.

[0080] FIG. 1 is a schematic diagram illustrating a wind turbine,

[0081] FIG. 2 is a schematic diagram illustrating a wind turbine blade and a spar cap structure arranged within the wind turbine blade,

[0082] FIG. 3 is a schematic diagram illustrating the simplest embodiment of a spar cap,

[0083] FIG. 4 is a schematic diagram illustrating another embodiment of a spar cap,

[0084] FIG. 5 is a schematic diagram illustrating a top view of different embodiments of an interlayer,

[0085] FIG. 6 is a schematic diagram illustrating a front view of different embodiments of a spar cap,

[0086] FIG. 7 is a schematic diagram illustrating a side view of different embodiments of a spar cap, and

[0087] FIG. 8 is a schematic diagram illustrating a top view of different embodiments of interlayer sheets,

[0088] FIG. 9 is a schematic diagram illustrating a cross-sectional view of an embodiment of an interlayer sheet with overlapping sections, and

[0089] FIG. 10 is a schematic diagram illustrating a cross-sectional view of an embodiment of an interlayer sheet with carbon fibres extending through it.

DETAILED DESCRIPTION

[0090] Various exemplary embodiments and details are described hereinafter, with reference to the figures when relevant. It should be noted that the figures may or may not be drawn to scale and that elements of similar structures or functions are represented by like reference numerals throughout the figures. It should also be noted that the figures are only intended to facilitate the description of the embodiments. They are not intended as an exhaustive description of the disclosure or as a limitation on the scope of the disclosure. In addition, an illustrated embodiment needs not have all the aspects or advantages shown. An aspect or an advantage described in conjunction with a particular embodiment is not necessarily limited to that embodiment and can be practiced in any other embodiments even if not so illustrated, or if not so explicitly described.

[0091] FIG. 1 illustrates a conventional modern upwind wind turbine according to the so-called “Danish concept” with a tower 400, a nacelle 600 and a rotor with a substantially horizontal rotor shaft. The rotor includes a hub 800 and three blades 1000 extending radially from the hub 800, each having a blade root 1600 nearest the hub and a blade tip 1400 furthest from the hub 800.

[0092] FIG. 2A shows a schematic view of a first embodiment of a wind turbine blade 1000. The wind turbine blade 1000 has the shape of a conventional wind turbine blade and comprises a root region 3000 closest to the hub, a profiled or an airfoil region 3400 furthest away from the hub and a transition region 3200 between the root region 3000 and the airfoil region 3400. The blade 1000 comprises a leading edge 1800 facing the direction of rotation of the blade 1000, when the blade is mounted on the hub, and a trailing edge 2000 facing the opposite direction of the leading edge 1800.

[0093] The airfoil region 3400 (also called the profiled region) has an ideal or almost ideal blade shape with respect to generating lift, whereas the root region 3000 due to structural considerations has a substantially circular or elliptical cross-section, which for instance makes it easier and safer to mount the blade 1000 to the hub. The diameter (or the chord) of the root region 3000 may be constant along the entire root area 3000. The transition region 3200 has a transitional profile gradually changing from the circular or elliptical shape of the root region 3000 to the airfoil profile of the airfoil region 3400. The chord length of the transition region 3200 typically increases with increasing distance r from the hub. The airfoil region 3400 has an airfoil profile with a chord extending between the leading edge 1800 and the trailing edge 2000 of the blade 1000. The width of the chord decreases with increasing distance r from the hub.

[0094] A shoulder 4000 of the blade 1000 is defined as the position, where the blade 1000 has its largest chord length. The shoulder 4000 is typically provided at the boundary between the transition region 3200 and the airfoil region 3400.

[0095] 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.

[0096] FIG. 2B is a schematic diagram illustrating a cross sectional view of an exemplary wind turbine blade 1000, e.g. a cross sectional view of the airfoil region of the wind turbine blade 1000. The wind turbine blade 1000 comprises a leading edge 1800, a trailing edge 2000, a pressure side 2400, and a suction side 2600. The wind turbine blade 1000 comprises spar caps 10 including a first spar cap 10a, and a second spar cap 10b. The wind turbine blade 1000 comprises a chord line 3800 between the leading edge 1800 and the trailing edge 2000. The wind turbine blade 1000 comprises shear webs 4200, such as a leading edge shear web and a trailing edge shear web. The shear webs 4200 could alternatively be a spar box with spar sides, such as a trailing edge spar side and a leading edge spar side. The spar caps 10, 10a, 10b may predominantly comprise carbon fibres, but may also or alternatively comprise glass fibres. The spar caps 10, 10a, 10b may comprise other fibres. The remainder of the shell parts 2400, 2600 may predominantly or entirely comprise glass fibres.

[0097] FIG. 3 schematically shows an embodiment of a spar cap 10 for a wind turbine blade according to the present disclosure. The spar cap illustrated in FIG. 3 may form part of a spar cap arranged in a wind turbine blade 1000, such as the spar caps 10, 10a, 10b of the wind turbine blade 1000 as illustrated in FIG. 2.

[0098] FIG. 3A is a schematic diagram showing a three-dimensional view of the spar cap 10, FIG. 3B illustrates a cross-sectional view along the width of the spar cap 10 and FIG. 3C shows an exploded view of the spar cap of FIG. 3B.

[0099] The spar cap in FIG. 3 comprises a first spar cap layer 20a, a second spar cap layer 20b and a first interlayer 30 arranged between the first spar cap layer 20a and the second spar cap layer 20b.

[0100] The first and second spar cap layers 20a, 20b in FIG. 3 consist of a first and second primary pre-cured fibre-reinforced element 21a, 22a, respectively.

[0101] The first primary pre-cured fibre reinforced element 21a and the second primary pre-cured fibre reinforced element 22a, i.e. the first and second spar cap layer 20a, 20b, and the first interlayer, each have a length, a width and a thickness. The width and length of the first interlayer 30 is substantially the same as the width and length, respectively, of the first and/or second primary pre-cured fibre reinforced elements 21a, 22a i.e. the first and second spar cap layers 20a, 20b. However, in some embodiments, the first and second primary pre-cured fibre-reinforced elements 21a, 22a are not necessarily the same size and the width and the length of the first interlayer 30 may be only substantially the same as the smallest of the first and second spar cap layers 20a, 20b or even smaller than the smallest spar cap layer.

[0102] The first spar cap layer 20a, the second spar cap layer 20b and the first interlayer 30 each have a first surface area 20aa, 20ba, 30a and an opposite second surface area 20ab, 20bb, 30b. The first surface area 20aa of the first spar cap layer 20a is defined by the width and length of the first spar cap layer 20a, the first surface area 20ba of the second spar cap layer 20b is defined by the width and length of the second spar cap layer 20b and the first surface area 30a of the first interlayer 30 is defined by the width and length of the first interlayer 30.

[0103] The first surface area 30a of the first interlayer 30 is in contact with the second surface area 20ab of the first spar cap layer 20a and the second surface area 30b of the first interlayer 30 is in contact with the first surface area 20ba of the second spar cap layer 20b.

[0104] In the embodiment illustrated in FIG. 3, the length and width of the first and second spar cap layers 20a, 20b equals the length and width of the spar cap 10, whereas the thickness of the spar cap is the aggregated thickness of the first interlayer 30 and the first and second spar cap layers 20a 20b. In the event that the first and second spar cap layers 20a, 20b each consists of a single primary pre-cured fibre reinforced element 21a, 21b, the length and width of the first and second primary pre-cured fibre reinforced element 21a, 21b would equal the length and width of the spar cap 10, whereas the thickness of the spar cap would be the aggregated thickness of the first interlayer 30 and the first and second primary pre-cured fibre reinforced element 21a, 21b.

[0105] In the embodiment of FIG. 3, the first interlayer comprises a first primary interlayer area 31a comprising a first interlayer sheet 33 comprising a first plurality of fibres. Furthermore, the first interlayer 30 comprises a second primary interlayer area 32a comprising a second interlayer sheet 34 comprising a second plurality of fibres. The first primary interlayer area 31a extends along the whole width and a first part of the length of the first interlayer 30, whereas the second primary interlayer area 32a extends along the whole width and a second part of the length of the first interlayer 30. The first plurality of fibres is of a different type than the second plurality of fibres. Thus, the spar cap 10 comprises a first interlayer 30, wherein the fibre material varies along the length of the spar cap 10. Alternatively or additionally, fibre ratio and/or density of the first interlayer sheet 33 may be different than fibre ratio and/or density of the second interlayer sheet 34.

[0106] Since the risk of different failure modes differs along the span of a wind turbine blade, it is advantageous to vary the characteristics of a spar cap placed therein, along its length, to optimize the spar cap, and thereby the wind turbine blade.

[0107] In a preferred embodiment, the first interlayer sheet is a polyester veil and the second interlayer sheet is a bidirectional glass-fibre fabric. The use of polyester veil in the interlayer promotes resin infusion, provides wetting of the area between spar cap layers and reduces the amount of defects. Furthermore, polyester veils reduce the fractures toughness. Bidirectional glass fibre fabrics are particularly suitable for part of the spar cap, providing structural bridging and strength in the gap between neighbouring fibre-reinforced elements, but have a lower fracture toughness than other materials. The present inventors have found that the combination of polyester veils and bidirectional glass fibre fabrics in an interlayer facilitates to optimize the mechanical properties of the final spar cap 10.

[0108] Preferably, the plurality of pre-cured fibre-reinforced elements 21a, 22a and the first interlayer 30 are embedded in a first cured resin. This may be done in an offline pre-form mould or directly in a blade mould. Preferably, each of the plurality of pre-cured fibre reinforced elements 21a, 22a are pultruded carbon planks, such as pultruded carbon fibre reinforced plastic planks.

[0109] Although not specifically illustrated, interlayers, such as the first interlayer 30, may also be provided between adjacent elements in the width direction, to facilitate resin flow between elements also in this direction.

[0110] FIG. 4 shows another exemplary embodiment of a spar cap 10 for a wind turbine blade according to the present disclosure. The spar cap illustrated in FIG. 4 may form part of a spar cap arranged in a wind turbine blade 1000, such as the spar caps 10 of the wind turbine blade 1000 as illustrated in FIG. 2. FIG. 4A is a schematic diagram showing a three-dimensional view of the spar cap 10, whereas FIG. 4B illustrates a cross-sectional view along the width of the spar cap 10 of FIG. 4A.

[0111] The spar cap in FIG. 4 comprises a first spar cap layer 20a, a second spar cap layer 20b and a third spar cap layer 20c. The spar cap 10 comprises a first interlayer 30 arranged between the first spar cap layer 20a and the second spar cap layer 20b and a second interlayer 40 arranged between the second spar cap layer 20b and the third spar cap layer 20c.

[0112] The first, second and third spar cap layers 20a, 20b, 20c each comprise three pre-cured fibre-reinforced elements 21, 22, 23, including a primary pre-cured fibre-reinforced element 21a, 22a, 23a, a secondary pre-cured fibre-reinforced element 21b, 22b, 23b and a tertiary pre-cured fibre-reinforced element 21c, 22c, 23c.

[0113] Each pre-cured fibre-reinforced element have a length, a width and a thickness, wherein the length is longer than the width, and the width is larger than the thickness.

[0114] In each layer, the secondary pre-cured fibre-reinforced element 21b, 22b, 23b is arranged between the primary and tertiary pre-cured fibre-reinforced element 21a, 22a, 23a, 21c, 22c, 23c, such that a first side of the primary pre-cured fibre-reinforced element 21a, 22a, 23a, defined by its thickness and length, is arranged adjacent to a second side of the secondary pre-cured fibre-reinforced element 21b, 22b, 23b, defined by its thickness and length, and such that a first side of the secondary pre-cured fibre-reinforced element 21b, 22b, 23b, defined by its thickness and length, is arranged adjacent to a second side of the tertiary pre-cured fibre-reinforced element 21c, 22c, 23c, defined by its thickness and length.

[0115] The first and second interlayer 30, 40 and the first, second and third spar cap layers 20a, 20b, 20c each have a length, a width and a thickness. In the embodiment illustrated in FIG. 4, the width and length of the first and second interlayers 30, 40 are substantially the same as the width and length, respectively, of the first, second and third spar cap layer 20a, 20b, 20c.

[0116] The first, second and third spar cap layers 20a, 20b, 20c and the first and second interlayers 30, 40 further each have a first surface area 20aa, 20ba, 20ca, 30a, 40a and an opposite second surface area 20ab, 20bb, 20cb, 30b, 40b. The first surface area 20aa of the first spar cap layer 20a is defined by the width and length of the first spar cap layer 20a, the first surface area 20ba of the second spar cap layer 20b is defined by the width and length of the second spar cap layer 20b and the first surface area 20ca of the third spar cap layer 20c is defined by the width and length of the third spar cap layer 20c. The first surface area 30a of the first interlayer 30 is defined by the width and length of the first interlayer 30 and the first surface area 40a of the second interlayer 40 is defined by the width and length of the second interlayer 40.

[0117] The first surface area 30a of the first interlayer 30 is in contact with the second surface area 20ab of the first spar cap layer 20a and the second surface area 30b of the first interlayer 30 is in contact with the first surface area 20ba of the second spar cap layer 20b. The first surface area 40a of the second interlayer 40 is in contact with the second surface area 20bb of the second spar cap layer 20b and the second surface area 40b of the second interlayer 40 is in contact with the first surface area 20ca of the third spar cap layer 20c.

[0118] In the embodiment illustrated in FIG. 4, the length and width of the first, second and third spar cap layers 20a, 20b, 20c equals the length and width of the spar cap 10, whereas the thickness of the spar cap is the aggregated thickness of the first interlayer 30, the second interlayer 40 and the first, second and third spar cap layers 20a, 20b, 20c. In the embodiment illustrated in FIG. 4, the length of the pre-cured fibre reinforced elements 21a,21b, 21c, 22a,22b, 22c, 22a,22b, 22c equals the length of the spar cap 10. The width of the spar cap 10 is the aggregate width of the three fibre-reinforced elements arranged adjacent to each other, and the thickness of the spar cap is the aggregated thickness of the first and second interlayer 30, 40 as well as the first, second and third spar cap layers 20a, 20b, 20c.

[0119] The first and/or second interlayers 30, 40 each comprises a first primary interlayer area 31a and a first secondary interlayer area 31b. The first primary interlayer area 31a and the first secondary interlayer area 31b comprise a plurality of first interlayer sheets 33. The first interlayer sheets 33 comprises a first plurality of fibres. Furthermore, the first and/or second interlayers 30, 40 each comprises a second primary interlayer area 32a comprising a second interlayer sheet 34 comprising a second plurality of fibres. In some embodiments, the second primary interlayer area 32a may comprise a plurality of second interlayer sheets 34. The first primary interlayer area 31a extends along the whole width and a first part of the length of the interlayer 30,40. The second primary interlayer area 32a extends along the whole width and a second part of the length of the interlayer 30,40. The first secondary interlayer area 31b extends along the whole width and a third part of the length of the interlayer 30,40. Thus, the second primary interlayer area 32a may be located between the first primary interlayer area 31a and the first secondary interlayer area 31b. The first plurality of fibres, i.e. the fibres of the first interlayer sheets 33 of the first primary interlayer area 31a and the first secondary interlayer area 31b, may be of a different type than the second plurality of fibres, i.e. the fibres of the second interlayer sheet(s) 34 of the second primary interlayer area 32a. Thus, the spar cap comprises a first and/or second interlayer 30, 40, wherein the fibre material varies along the length direction, such that the outer edges of the spar cap 10 comprise one type of fibre material in the interlayers, and the middle part of the spar cap comprises another type.

[0120] The first interlayer 30 and the second interlayer 40 may be identical, as illustrated in FIG. 4. However, alternatively, they may be different, and the above description may apply to either of the first interlayer 30 or the second interlayer 40.

[0121] Preferably, the plurality of pre-cured fibre-reinforced elements and the plurality of interlayers are embedded in a first cured resin to form the finished spar cap. This may be done in an offline pre-form mould or directly in a blade mould.

[0122] Preferably, each of the plurality of pre-cured fibre reinforced elements are pultruded carbon planks, such as pultruded carbon fibre reinforced plastic planks.

[0123] Although not specifically illustrated, interlayers may also be provided between adjacent elements in the width direction, to facilitate resin flow between elements also in this direction.

[0124] FIG. 5 schematically illustrates five different embodiments of interlayers for a spar cap, seen from a top view, according to the present disclosure. The number of interlayers in a spar cap according to the present disclosure may be similar or identical. However, the different interlayers in a spar cap may also differ, such that the fibre type in the thickness direction of a spar cap varies. Any of the interlayers 30 as illustrated in FIG. 5 may substitute the interlayers 30, 40 of the embodiments of FIGS. 3, 4, 6 and/or 7.

[0125] FIG. 5A shows a first embodiment of an interlayer 30′ according to the present disclosure, configured to be arranged between a first spar cap layer and a second spar cap layer as described in FIGS. 3 and 4.

[0126] The interlayer 30′ comprises a first primary interlayer area 31a and a first secondary interlayer area 31b comprising first interlayer sheets 33. The first interlayer sheets comprises a first plurality of fibres. The interlayer 30′ comprises a second primary interlayer area 32a comprising a number of second interlayer sheets 34. The second interlayer sheets 34 comprises a second plurality of fibres, of a different type than the first plurality of fibres. The first primary interlayer area 31a extends along the whole width and a first part of the length of the interlayer 30′. The second primary interlayer area 32a extends along the whole width and a second part of the length of the interlayer 30′. The first secondary interlayer area 31b extends along the whole width and a third part of the length of the interlayer 30′. Thus, the second primary interlayer area 32a is located between the first primary interlayer area 31a and the first secondary interlayer area 31b. The interlayer 30′ is configured to be arranged in a spar cap, such that the fibre material varies along the length direction, such that the outer edges of the spar cap comprise one type of fibre material in the interlayers, and the middle part of the spar cap comprises another type of fibres.

[0127] FIG. 5B shows a second embodiment of an interlayer 30″ according to the present disclosure, configured to be arranged between a first spar cap layer and a second spar cap layer as described in FIGS. 3 and 4.

[0128] The interlayer 30″ comprises a plurality of first interlayer areas, such as four first interlayer areas, including a first primary interlayer area 31a, a first secondary interlayer area 31b, a first tertiary interlayer area 31c and a first quaternary interlayer area 31d. The first interlayer areas comprise a plurality of first interlayer sheets 33, such as one for each of the first interlayer areas. The first interlayer sheets 33 each comprises a first plurality of fibres. The interlayer 30″ comprises a plurality of second interlayer areas, such as three second interlayer areas, including a second primary interlayer area 32a, a second secondary interlayer area 32b and a second tertiary interlayer area 32c. The second interlayer areas comprise a plurality of second interlayer sheets 34, e.g. one for each of the second interlayer areas. The second interlayer sheets 34 each comprises a second plurality of fibres, different from the first plurality of fibres. The first primary, secondary, tertiary and quaternary interlayer areas 31a-31d extend along the whole width and a part of the length of the interlayer 30″. The second primary, secondary and tertiary interlayer areas 32a-32c also extends along the whole width and part of the length of the interlayer 30″. The first interlayer areas 31a-31d and the second interlayer areas 32a-32c are alternating along the length of the interlayer 30″.

[0129] Thus, the first interlayer is configured to be arranged in a spar cap, such that the fibre material varies along the length direction, such that parts of the spar cap comprise one type of fibre material in the interlayers, and some parts of the spar cap comprises another type.

[0130] FIG. 5C shows a third embodiment of an interlayer 30′″ according to the present disclosure, configured to be arranged between a first spar cap layer and a second spar cap layer as described in FIGS. 3 and 4.

[0131] The interlayer 30′″ comprises a first primary interlayer area 31a and a first secondary interlayer area 31b comprising a number of first interlayer sheets 33. The first interlayer sheets 33 comprises a first plurality of fibres. The interlayer 30′″ comprises a second primary interlayer area 32a comprising a number of second interlayer sheets 34. The second interlayer sheets comprises a second plurality of fibres, of a different type than the first plurality of fibres. The first primary interlayer area 31a extends along the whole length and a first part of the width of the interlayer 30′. The second primary interlayer area 32a extends along the whole length and a second part of the width of the interlayer 30′″. The first secondary interlayer area 31b extends along the whole length and a third part of the width of the interlayer 30′″. Thus, the second primary interlayer area 32a is located between the first primary interlayer area 31a and the first secondary interlayer area 31b. The first interlayer is configured to be arranged in a spar cap, such that the fibre material varies along the width, such that the outer edges of the spar cap comprise one type of fibre material in the interlayers, and the middle part of the spar cap comprises another type of fibres.

[0132] FIG. 5D shows a fourth embodiment of an interlayer 30″″ according to the present disclosure, configured to be arranged between a first spar cap layer and a second spar cap layer as described in FIGS. 3 and 4.

[0133] The interlayer 30″″ comprises a plurality of first interlayer areas, such as four first interlayer areas, including a first primary interlayer area 31a, a first secondary interlayer area 31b, a first tertiary interlayer area 31c and a first quaternary interlayer area 31d. The first interlayer areas comprise a plurality of first interlayer sheets 33, e.g. one for each first interlayer area. The first interlayer sheets 33 each comprises a first plurality of fibres. The interlayer 30″″ comprises a plurality of second interlayer areas, such as three second interlayer areas, including a second primary interlayer area 32a, a second secondary interlayer area 32b and a second tertiary interlayer area 32c. The second interlayer areas 32a-32c comprises a plurality of second interlayer sheets 34, e.g. one for each second interlayer area 32a-32c. The second interlayer sheets 34 each comprises a second plurality of fibres, different from the first plurality of fibres. The first primary, secondary, tertiary and quaternary interlayer areas 31a-31d extend along the whole length and a part of the width of the interlayer 30′. The second primary, secondary and tertiary interlayer area 32a-32c also extends along the whole length and part of the width of the first interlayer. The first interlayer areas 31a-31d and the second interlayer areas 32a-32c are alternating along the width of the interlayer 30″″. The first interlayer is configured to be arranged in a spar cap, such that the fibre material varies along the width direction, such that parts of the spar cap comprise one type of fibre material in the interlayers, and some parts of the spar cap comprises another type.

[0134] FIG. 5E shows a fifth embodiment of an interlayer 30 according to the present disclosure, configured to be arranged between a first spar cap layer and a second spar cap layer as described in FIGS. 3 and 4.

[0135] The interlayer 30 comprises a first primary interlayer area 31a comprising a number of interlayer sheets 33 comprising a first plurality of fibres. The interlayer 30 comprises a second primary interlayer area 32a comprising a number of interlayer sheets 34 comprising a second plurality of fibres, different from the first plurality of fibres. The first primary interlayer area 31a extends along the whole length and the whole width of the interlayer 30, in a way such that the second primary interlayer area 32a is surrounded by the first primary interlayer area 31a. The second primary interlayer area 32a extend along part of the length and a part of the width of the interlayer 30. Thereby, the first primary interlayer area 31a forms part of the perimeter of the interlayer 30. The interlayer 30 is configured to be arranged in a spar cap, such that the fibre material varies along the width direction and the length direction, such that inner parts of the spar cap comprise one type of fibre material in the interlayers, and outer parts of the spar cap comprises another type.

[0136] FIG. 6 schematically illustrates a front view of three different embodiments of a spar cap according to the present disclosure. By front view is meant, showing the thickness and width of the spar cap. The spar cap in FIG. 6 comprises three spar cap layers 20a, 20b, 20c, e.g. as described in relation to FIG. 3. Each of the spar cap layers has four pre-cured fibre reinforced elements arranged adjacent to each other. Furthermore, the spar cap in FIG. 6 comprises two identical interlayers i.e. a first and a second interlayer 30, 40.

[0137] FIG. 6A is a front view of a spar cap 10 comprising a first and second interlayer 30, 40 with a similar construction as the interlayer described in relation to FIG. 5C. FIG. 6B is a front view of a spar cap 10 comprising a first and second interlayer 30, 40 with a similar construction as the interlayer described in relation to FIG. 5D. FIG. 6C is a front view of a spar cap comprising a first and second interlayer 30, 40 with a similar construction as the interlayer described in relation to FIG. 5E.

[0138] FIG. 7 schematically illustrates a side view of three different embodiments of a spar cap 10 according to the present disclosure. By side view is meant, showing the thickness and length of the spar cap 10. The spar caps 10 in FIG. 7 comprises three spar cap layers 20a, 20b, 20c, e.g. as described in relation to FIG. 3. Furthermore, the spar cap in FIG. 7 comprises two identical interlayers i.e. a first and a second interlayer 30, 40.

[0139] FIG. 7A is a side view of a spar cap 10 comprising a first and second interlayer 30, 40 with a similar construction as the interlayer 30′ described in relation to FIG. 5A. FIG. 7B is a side view of a spar cap 10 comprising a first and second interlayer 30, 40 with a similar construction as the interlayer 30″ described in relation to FIG. 5B. FIG. 7C is a side view of a spar cap 10 comprising a first and second interlayer 30, 40 with a similar construction as the interlayer 30 described in relation to FIG. 5E.

[0140] FIG. 8 schematically illustrates an exemplary interlayer 30′, such as the interlayer 30′ as described with respect to FIG. 5A, showing that the number of first interlayer sheets 33 and/or the number of second interlayer sheets 34 may differ, even though the final interlayer 30′ is the same.

[0141] One interlayer sheet may be sufficient for an interlayer to be arranged between two spar cap layers. However, several interlayer sheets may also be used between two spar cap layers, together forming an interlayer. According to the present disclosure at least two interlayer sheets are preferably used, at least one first interlayer sheet comprising a first plurality of fibres and at least one second interlayer sheet comprising a second plurality of fibres, different from the first plurality of fibres. However, a single interlayer sheet comprising different fibres in different areas, could be used in the alternative. In practice, it may be easier to use two types of sheets, one comprising the first plurality of fibres and the other comprising the second plurality of fibres.

[0142] FIG. 8A illustrates the interlayer 30′ as described in relation to FIG. 5A, whereas FIG. 8B-8D illustrates how the number of first and second interlayer sheets 33, 34 in the interlayer according to FIG. 8A. may be varied, even though the final interlayers are similar.

[0143] FIG. 8B illustrates the simplest embodiment, where one first interlayer sheet 33 is used for the first primary interlayer area 31a and another first interlayer sheet 33 is used for the first secondary interlayer area 31b. One second interlayer sheet 34 is used for the second primary interlayer area 32a.

[0144] FIG. 8C illustrates another embodiment, where two first interlayer sheets 33 are used for the first primary interlayer area 31a and two other first interlayer sheets 33 are used for the first secondary interlayer area 31b. Two second interlayer sheets 34 are used for the second primary interlayer area 32a.

[0145] FIG. 8D illustrates a further embodiment, where one first interlayer sheet 33 is used for the first primary interlayer area 31a and another first interlayer sheet 33 is used for the first secondary interlayer area 31b. Furthermore, five second interlayer sheets 34 are used for the second primary interlayer area 32a.

[0146] Although not illustrated specifically, it can be realised that the other exemplary interlayers as illustrated in the previous figures, e.g. FIGS. 5B-5D may be assembled by a plurality of interlayer sheets, i.e. the first interlayer areas 31a-31d may comprise one or more, such as a plurality, of first interlayer sheets 33, and/or the second interlayer areas 32a-32c may comprise one or more, such as a plurality, of second interlayer sheets 34.

[0147] FIGS. 9A and 9B illustrates two alternative embodiments of a first interlayer 30 as illustrated in FIG. 7A. In FIG. 7A, the first number of interlayer sheets 33 and the second number of interlayer sheets 34 are arranged adjacent to each other, such that adjacent edges of the interlayer sheets 33, 34 are contacted with each other. However, in FIGS. 9A and 9B, the first number of interlayer sheets 33 and the second number of interlayer sheets 34 overlap each other in areas where they meet. Thus, the interlayer in FIG. 9 comprise different fibre layers both along the length-direction and in the thickness direction.

[0148] In some embodiments, as illustrated in FIG. 10, the first interlayer 30 comprises a plurality of carbon fibres 50 forming part of the first surface area of the first interlayer 30a as well as second surface area of the first interlayer 30b. Thus, the plurality of carbon fibres 50 extend through the first interlayer 30. Preferably, the carbon fibres 23 extend through all interlayer sheets present in the interlayer sheet 20. Thus, for the embodiments illustrated in FIG. 3-8, the carbon fibres 50 may extend through a single interlayer sheet. However, in the embodiment illustrated in FIG. 9, the carbon fibres 50 may extend through the overlapping interlayer sheets i.e. through two interlayer sheets arranged on top of each other. In this way, electrical conductivity through the interlayer may be obtained, which facilitates electron flow between elements, such as pultruded elements, when sandwiched therebetween.

LIST OF REFERENCE NUMERALS

[0149] 10 spar cap [0150] 10a first spar cap [0151] 10b second spar cap [0152] 20 spar cap layers [0153] 20a first spar cap layer [0154] 20aa first surface area of first spar cap layer [0155] 20ab second surface area of first spar cap layer [0156] 20b second spar cap layer [0157] 20ba first surface area of second spar cap layer [0158] 20bb second surface area of second spar cap layer [0159] 20c third spar cap layer [0160] 21,22,23 pre-cured fibre-reinforced elements [0161] 21a first primary pre-cured fibre-reinforced element [0162] 21b first secondary pre-cured fibre-reinforced element [0163] 21c first tertiary pre-cured fibre-reinforced element [0164] 22a second primary pre-cured fibre-reinforced element [0165] 22b second secondary pre-cured fibre-reinforced element [0166] 22c second tertiary pre-cured fibre-reinforced element [0167] 23a third primary pre-cured fibre-reinforced element [0168] 23b third secondary pre-cured fibre-reinforced element [0169] 23c third tertiary pre-cured fibre-reinforced element [0170] 30 first interlayer [0171] 30a first surface area of first interlayer [0172] 30b second surface area of first interlayer [0173] 31 first interlayer area [0174] 31a first primary interlayer area [0175] 31b first secondary interlayer area [0176] 32 second interlayer area [0177] 32a second primary interlayer area [0178] 32b second secondary interlayer area [0179] 33 first interlayer sheet [0180] 34 second interlayer sheet [0181] 35 first plurality of fibres [0182] 36 second plurality of fibres [0183] 40 second interlayer [0184] 50 carbon fibres extending through the first interlayer [0185] L length [0186] W width [0187] T thickness [0188] 200 wind turbine [0189] 400 tower [0190] 600 nacelle [0191] 800 hub [0192] 1000 blade [0193] 1400 blade tip [0194] 1600 blade root [0195] 1800 leading edge [0196] 2000 trailing edge [0197] 2400 pressure side [0198] 2600 suction side [0199] 3000 root region [0200] 3200 transition region [0201] 3400 airfoil region [0202] 3800 chord line [0203] 4000 shoulder/position of maximum chord [0204] 4200 shear web