Wind Turbine Rotor Blade Components and Methods of Making Same

• US 20110243750A1
• Filed: 01/14/2011
• Published: 10/06/2011
• Est. Priority Date: 01/14/2010
• Status: Abandoned Application

• Current Assignee: Senvion GmbH (Senvion SE)
• Original Assignee: NEPTCO, Inc. (Chase Corporation)
• Inventors: Franklin, Ethan, Narasimhan, Kameshwaran, Gruhn, Joel D.
• Application Number:
  US13/007,111
• Publication Number:
  US 20110243750A1
• Time in Patent Office: Days
• US Class Current: 416/226
• CPC Class Codes: B23P 15/04 turbine or like blades from several pieces
• CPC Class Codes: B29B 11/16 comprising fillers or reinforcement non-woven fabrics per se D04H1/00, D04H3/00
• CPC Class Codes: B29C 70/023 with reinforcing inserts
• CPC Class Codes: B29C 70/083 Combinations of continuous fibres or fibrous profiled structures oriented in one direction and reinforcements forming a two dimensional structure, e.g. mats B29D24/00, B29D99/001 take precedence
• CPC Class Codes: B29D 99/0028 hollow blades
• CPC Class Codes: B29L 2031/085 Wind turbine blades
• CPC Class Codes: F03D 1/0675 of the blades
• CPC Class Codes: F03D 80/00 Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
• CPC Class Codes: F03D 9/25 the apparatus being an electrical generator F03D9/22 takes precedence
• CPC Class Codes: F05B 2220/30 in turbines
• CPC Class Codes: F05B 2230/20 essentially without removing material
• CPC Class Codes: F05B 2240/2211 of the multibladed, low speed, e.g. "American farm" type
• CPC Class Codes: F05B 2280/6003 Composites; e.g. fibre-reinforced
• CPC Class Codes: Y02E 10/72 Wind turbines with rotation axis in wind direction
• CPC Class Codes: Y02E 10/74 Wind turbines with rotation axis perpendicular to the wind direction
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 29/49337 Composite blade
• CPC Class Codes: Y10T 29/49632 Metal reinforcement member for nonmetallic, e.g., concrete, structural element
• CPC Class Codes: Y10T 29/49787 Obtaining plural composite product pieces from preassembled workpieces
• CPC Class Codes: Y10T 29/4979 : Breaking through weakened portion

Abstract

Structural preform layers of multiple rigid unidirectional strength elements or rods are constructed and arranged for use in fabricating load-bearing support structures and reinforcements of wind turbine blades. Individual preform layers include multiple elongate unidirectional strength elements or rods arranged in a single layer along a longitudinal axis of the preform layer. Each preform layer includes one or more fibrous carrier layers to which the multiple strength elements or rods are joined and arranged in the single layer. Each strength element or rod is longitudinally oriented and adjacent to other elements or rods. Individual strength elements or rods include a mass of substantially straight unidirectional structural fibers embedded within a matrix resin such that the elements or rods have a substantially uniform distribution of fibers and high degree of fiber collimation. The relative straightness of the fibers and fiber collimation provide strength elements or rods and the preform layers with high rigidity and significant compression strength.

Claims

1. A spar cap for a wind turbine blade comprising:

a composite beam constructed as a structural support component to extend along at least a portion of the span of the blade;

the composite beam including one or more preform layers of multiple elongate and rigid unidirectional strength elements or rods arranged in a single layer along a longitudinal axis of the preform layer;

the preform layer including at least one fibrous carrier layer to which the strength elements or rods are joined to retain the strength elements or rods in the single layer;

each preform layer being stacked or layered with at least one of;

one or more other preform layers and multiple fibrous layers, wherein

multiple stacked or layered preform layers define wholly or partially a thickness of the composite beam.