Wind turbine rotor blade components and methods of making same

• US 9,394,882 B2
• Filed: 10/31/2014
• Issued: 07/19/2016
• Est. Priority Date: 01/14/2010
• Status: Active Grant

• Current Assignee: Senvion GmbH (Senvion SE)
• Original Assignee: Senvion GmbH (Senvion SE)
• Inventors: Gruhn, Joel D., Franklin, Ethan, Narasimhan, Kameshwaran
• Primary Examiner(s): White, Dwayne J
• Assistant Examiner(s): Beebe, Joshua R
• Application Number:
  US14/530,071
• Publication Number:
  US 20150078911A1
• Time in Patent Office: 627 Days
• Field of Search: 416/230, 416/226, 416/241.A
• US Class Current: 1/1
• 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 continuous web of multiple preform layers comprising:

each preform layer of the multiple preform layers including multiple elongate strength rods arranged longitudinally relative to one another in a single layer, each strength rod being disposed adjacent to, co-planar with and spaced from at least one adjacent strength rod;

each strength rod including multiple unidirectional, substantially straight collimated structural fibers fixed in a solidified matrix resin so that each strength rod is rigid and defines a finished geometry including a selected length and width and a selected profile;

each preform layer including at least one carrier layer to which the multiple strength rods are joined by an adhesive applied to at least one of the carrier layer and the strength rods;

wherein the carrier layer locates adjacent strength rods a fixed distance apart, further comprising each preform layer being adjacent to and connected with at least one other preform layer along a transverse width of the preform layers along the continuous web;

a tapered end zone defined between two adjacent and connected preform layers, the tapered end zone including a tapering end portion extending from one end of each adjacent preform layer, wherein the tapering end portion extends from each adjacent preform layer at a certain rate of taper,

wherein the tapered end zone has a reduced thickness along at least one point to facilitate separation of the two adjacent preform layers from one another.

2. The continuous web of claim 1, wherein at least two of the multiple preform layers have different lengths.

3. The continuous web of claim 1, wherein at least two of the multiple preform layers have different rates of taper.

4. The continuous web of claim 1, wherein at least two of the multiple preform layers have the same lengths.

5. The continuous web of claim 1, wherein at least two of the multiple preform layers have the same rate of taper.

6. The continuous web of claim 1, wherein the reduced thickness of the tapered end zone is sufficiently thin to facilitate separation.

7. The continuous web of claim 6, wherein the separation by one or more of cutting or grinding.

8. The continuous web of claim 6, wherein the reduced thickness is about 5% to about 50% of an untapered thickness of the continuous web.

9. The continuous web of claim 6, wherein the reduced thickness is about 20% of an untapered thickness of the continuous web.

10. The continuous web of claim 1, wherein the web is configured in one of:

a coil or wrapped along one of a reel or spool.