IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0757832
(2010-04-09)
|
등록번호 |
US-8192169
(2012-06-05)
|
발명자
/ 주소 |
|
출원인 / 주소 |
|
대리인 / 주소 |
|
인용정보 |
피인용 횟수 :
3 인용 특허 :
11 |
초록
▼
A wind turbine rotor blade and a wind turbine incorporating the rotor blade include a first and second composite skin. A first and a second spar pultrusion having a base and a plurality of integral ribs generally normal to the base are attached to the inside surface of the first and second composite
A wind turbine rotor blade and a wind turbine incorporating the rotor blade include a first and second composite skin. A first and a second spar pultrusion having a base and a plurality of integral ribs generally normal to the base are attached to the inside surface of the first and second composite skins and extend the span of the rotor blade. At least one shear web connects a rib of the first spar pultrusion to a corresponding rib of the second spar pultrusion. The width of the spar pultrusions decreases in a step-wise fashion along the span of the rotor blade from the root to the tip. The leading or trailing edge of the rotor blade may be selectably opened for inspection and repair.
대표청구항
▼
1. A wind turbine rotor blade, the rotor blade defining a leading edge, a trailing edge, a rotor blade root, a rotor blade tip, a chord and a span, the rotor blade comprising: a. a first composite skin and a second composite skin, each of said first and said second composite skins having an inside s
1. A wind turbine rotor blade, the rotor blade defining a leading edge, a trailing edge, a rotor blade root, a rotor blade tip, a chord and a span, the rotor blade comprising: a. a first composite skin and a second composite skin, each of said first and said second composite skins having an inside surface, each of said first and said second composite skins defining a composite skin root end defining said rotor blade root and a composite skin tip end defining said rotor blade tip;b. a first spar and a second spar, said first and said second spars being elongated, said first and said second spars each having a spar base and a plurality of elongated ribs attached to and generally normal to said base, said spar having a spar root end and a spar tip end, said base of said first spar being bonded to said inside surface of said first composite skin, said base of said second spar being bonded to said inside surface of said second composite skin, said spar root end of said first and said second spars being located proximal to said rotor blade root, said spar tip end of said first and said second spars being located proximal to said rotor blade tip;c. at least one shear web, said shear web having a first shear web edge and an opposing second shear web edge, said first shear web edge being attached to a rib of said first spar, said second shear web edge being attached to a rib of said second spar, at least one of said ribs not being attached to said first shear web edge or said second shear web edge at a location along said first spar or said second spar. 2. The rotor blade of claim 1 wherein said first spar and said second spar each has an elongated dimension and said base has a width normal to said elongated dimension, said width decreasing along said elongated dimension of said first and said second spars from said spar root end to said spar tip end, said plurality of ribs being in a spaced apart relation along said width, said plurality of ribs having a number, said number of said ribs decreasing in a step-wise fashion along said elongated dimension of said first and said second spar from said spar root end to said spar tip end, said first and said second spars being composed of a spar reinforcing fiber and a spar thermoset resin. 3. The rotor blade of claim 2 wherein each said rib of said first spar and said second spar each has a depth, said depth of each said rib decreasing along said elongated dimension of said first and said second spars from said root end to said tip end, said plurality of ribs and said base defining each said spar being composed of a single piece. 4. The rotor blade of claim 2 wherein said shear web comprises a one of a plurality of said shear webs, each said shear web having said first shear web and said second shear web edge, each said first shear web edge of each said shear web being attached to a one of said ribs of said first spar, each said second shear web edge of each said shear web being attached to a one of said ribs of said second spar. 5. The rotor blade of claim 2 wherein said turbine rotor blade further comprising: a leading edge skin, said leading edge skin extending from said rotor blade root to said rotor blade tip, said leading edge skin defining said leading edge, said leading edge skin having a hinged attachment to a one of said first skin and said second skin. 6. The rotor blade of claim 2 wherein said first composite skin and said second composite skin each defines a trailing edge portion, said trailing edge portions of said first and said second composite skins having a releasable attachment joining one of said first and said second composite skins to the other to define said turbine rotor blade trailing edge, said releasable attachment being proximal to said trailing edge. 7. The rotor blade of claim 2 wherein said first spar comprises: a plurality of said first spars, each of said plurality of first spars having said base and having said plurality of ribs attached to said base, each said base of said plurality of said first spars being bonded to said first inside surface of said first skin such that one said rib of a one of said plurality of first spars is adjacent to another said rib of another of said plurality of first spars, said first shear web edge being attached to said one said rib and to said adjacent another said rib. 8. The rotor blade of claim 7 wherein said second spar comprises: a plurality of said second spars, each of said plurality of second spars having said base and having said plurality of ribs attached to said base, each said base of said plurality of said second spars being bonded to said second inside surface of said second skin such that one said rib of a one of said plurality of second spars is adjacent to another said rib of another of said plurality of second spars, said second shear web edge being attached to said one said rib of said one of said second spars and to said adjacent another said rib of said another of said second spars. 9. A wind turbine rotor blade, the rotor blade defining a leading edge, a trailing edge, a rotor blade root, a rotor blade tip, a chord and a span, the rotor blade comprising: a. a first composite skin and a second composite skin, each of said first and said second composite skins having an inside surface, each of said first and said second composite skins defining a composite skin root end defining said rotor blade root and a composite skin tip end defining said rotor blade tip;b. a first spar and a second spar, said first and said second spars being elongated, said first and said second spars each having a spar base and a plurality of elongated ribs attached to and generally normal to said base, said spar having a spar root end and a spar tip end, said base of said first spar being bonded to said inside surface of said first composite skin, said base of said second spar being bonded to said inside surface of said second composite skin, said spar root end of said first and said second spars being located proximal to said rotor blade root, said spar tip end of said first and said second spars being located proximal to said rotor blade tip;c. at least one shear web, said shear web each having a first shear web edge and an opposing second shear web edge, said first shear web edge being attached to a one of said ribs of said first spar, said second shear web edge being attached to a one of said ribs of said second spar, wherein said first spar and said second spar each has an elongated dimension and said base has a width normal to said elongated dimension, said width decreasing in a step-wise fashion along said elongated dimension of said first and said second spar from said spar root end to said spar tip end, said first and said second spars being composed of a spar reinforcing fiber and a spar thermoset resin, said shear web comprising:d. a first shear web skin;e. a second shear web skin;f. a shear web core, said first and said second shear web skins being strong compared to said shear web core, said first and said second shear web skins being attached to opposing sides of said shear web core, said shear web having a first shear web edge and a second shear web edge;g. a first connector and a second connector, said first and said second connectors comprising a connector thermoset resin and a connector reinforcing fiber, said first connector being bonded to a one of said first and said second shear web edges and to a one of said ribs of said first spar, said second connector being bonded to the other of said first and said second shear web edges and to one of said ribs of said second spar;h. a plurality of pin members, a plurality of holes being defined by first and said second connectors and said ribs to which said first and said second connectors are bonded, each of said pin members being disposed within a one of said holes. 10. A wind turbine rotor blade, the rotor blade defining a leading edge, a trailing edge, a rotor blade root, a rotor blade tip, a chord and a span, the rotor blade comprising: a. a first composite skin and a second composite skin, each of said first and said second composite skins having an inside surface, each of said first and said second composite skins defining a composite skin root end defining said rotor blade root and a composite skin tip end defining said rotor blade tip;b. a first spar and a second spar, said first and said second spars being elongated, said first and said second spars each having a spar base and a plurality of elongated ribs attached to and generally normal to said base, said spar having a spar root end and a spar tip end, said base of said first spar being bonded to said inside surface of said first composite skin, said base of said second spar being bonded to said inside surface of said second composite skin, said spar root end of said first and said second spars being located proximal to said rotor blade root, said spar tip end of said first and said second spars being located proximal to said rotor blade tip;c. at least one shear web, said shear web each having a first shear web edge and an opposing second shear web edge, said first shear web edge being attached to a one of said ribs of said first spar, said second shear web edge being attached to a one of said ribs of said second spar, wherein said first spar and said second spar each has an elongated dimension and said base has a width normal to said elongated dimension, said width decreasing in a step-wise fashion along said elongated dimension of said first and said second spar from said spar root end to said spar tip end, said first and said second spars being composed of a spar reinforcing fiber and a spar thermoset resin,d. a leading edge skin, said leading edge skin extending from said rotor blade root to said rotor blade tip, said leading edge skin defining said leading edge, said leading edge skin having a releasable attachment to each of said first skin and to said second skin wherein said releasable attachment between said leading edge skin and said first and said second composite skins comprising:e. a composite skin hinge, said composite skin hinge being bonded to said first composite skin or said second composite skin; andf. a leading edge skin hinge, said leading edge skin hinge being attached to said leading edge skin, said leading edge skin hinge matably engaging said composite skin hinge; andg. a retaining pin, said retaining pin engaging said composite skin hinge and said leading edge skin hinge, said retaining pin holding said leading edge skin hinge and said composite hinge in engagement. 11. A wind turbine rotor blade, the rotor blade defining a leading edge, a trailing edge, a rotor blade root, a rotor blade tip, a chord and a span, the rotor blade comprising: a. a first composite skin and a second composite skin, each of said first and said second composite skins having an inside surface, each of said first and said second composite skins defining a composite skin root end defining said rotor blade root and a composite skin tip end defining said rotor blade tip;b. a first spar and a second spar, said first and said second spars being elongated, said first and said second spars each having a spar base and a plurality of elongated ribs attached to and generally normal to said base, said spar having a spar root end and a spar tip end, said base of said first spar being bonded to said inside surface of said first composite skin, said base of said second spar being bonded to said inside surface of said second composite skin, said spar root end of said first and said second spars being located proximal to said rotor blade root, said spar tip end of said first and said second spars being located proximal to said rotor blade tip;c. at least one shear web, said shear web each having a first shear web edge and an opposing second shear web edge, said first shear web edge being attached to a one of said ribs of said first spar, said second shear web edge being attached to a one of said ribs of said second spar, wherein said first spar and said second spar each has an elongated dimension and said base has a width normal to said elongated dimension, said width decreasing in a step-wise fashion along said elongated dimension of said first and said second spar from said spar root end to said spar tip end, said first and said second spars being composed of a spar reinforcing fiber and a spar thermoset resin,wherein said first composite skin and said second composite skin each defines a trailing edge portion, said trailing edge portions of said first and said second composite skins having a releasable attachment joining one of said first and said second composite skins to the other to define said turbine rotor blade trailing edge, wherein said releasable attachment of said trailing edge portions further comprises: a mechanical lock, said mechanical lock having a male portion and a female portion, said male portion being bonded to a one of said first and said second composite skins, said female portion being bonded to the other of said first and said second composite skins, said male portion being releasably retained by said female portion. 12. A wind turbine, the wind turbine comprising: a. a tower;b. an electrical generator, said electrical generator being supported above a ground by said tower;c. a rotor blade, said rotor blade having an axis of rotation, said tower supporting said rotor blade above said ground, said rotor blade being operably connected to said electrical generator, said rotor blade defining a leading edge, a trailing edge, a rotor blade root, a rotor blade tip, a chord and a span, said rotor blade further comprising: i. a first composite skin and a second composite skin, each of said first and said second composite skins having a composite skin root end defining said rotor blade root and a composite skin tip end defining said rotor blade tip;ii. a first spar and a second spar, said first and said second spars being elongated, each of said first and said second spars having a spar base and a plurality of elongated ribs attached to and generally normal to said spar base, each of said first and said second spars having a spar root end and a spar tip end, said first spar being bonded to said inside surface of said first composite skin, said second spar being bonded to said inside surface of said second composite skin, said spar root end of said first and said second spars being located proximal to said rotor blade root, said spar tip end of said first and said second spars being located proximal to said rotor blade tip;iii. at least one shear web, said shear web having a first shear web edge and an opposing second shear web edge, said first shear web edge being attached to a one of said ribs of said first spar, said second shear web edge being attached to a one of said ribs of said second spar, at least a one of said ribs not being attached to said first shear web edge or said second shear web edge at a location along said first spar or said second spar. 13. The wind turbine of claim 12 wherein said first spar and said second spar each has an elongated dimension and said spar base has a width normal to said elongated dimension, said width decreasing along said elongated dimension of said first and said second spars from said spar root end to said spar tip end, said plurality of ribs being in a spaced apart relation along said width, said plurality of ribs having a number, said number of said ribs decreasing in a step-wise fashion along said elongated dimension of said first and said second spars from said spar root end to said spar tip end, said first and said second spars being composed of a spar reinforcing fiber and a spar thermoset resin. 14. The wind turbine of claim 13 wherein each said rib of said first spar and said second spar each has a depth, said depth of each said rib decreasing along said elongated dimension of said first and said second spars from said root end to said tip end, said plurality of ribs and said base defining each said spar being of a single piece. 15. The wind turbine of claim 14 wherein said rotor blade further comprising: a leading edge skin, said leading edge skin extending from said rotor blade root to said rotor blade tip, said leading edge skin defining said leading edge, said leading edge skin having a releasable attachment to each of said first skin and to said second skin. 16. A wind turbine, the wind turbine comprising: a. a tower;b. an electrical generator, said electrical generator being supported above a ground by said tower;c. a rotor blade, said rotor blade having an axis of rotation, said tower supporting said rotor blade above said ground, said rotor blade being operably connected to said electrical generator, said rotor blade defining a leading edge, a trailing edge, a rotor blade root, a rotor blade tip, a chord and a span, said rotor blade further comprising: i. a first composite skin and a second composite skin, each of said first and said second composite skins having a composite skin root end defining said rotor blade root and a composite skin tip end defining said rotor blade tip;ii. a first spar and a second spar, said first and said second spars being elongated, each said first and said second spar having a spar base and a plurality of elongated ribs attached to and generally normal to said spar base, each said first and said second spar having a spar root end and a spar tip end, said first spar being bonded to said inside surface of said first composite skin, said second spar being bonded to said inside surface of said second composite skin, said spar root end of said first and said second spar being located proximal to said rotor blade root, said spar tip end of said first and said second spars being located proximal to said rotor blade tip;iii. at least one shear web, said shear web each having a first shear web edge and an opposing second shear web edge, said first shear web edge being attached to a one of said ribs of said first spar, said second shear web edge being attached to a one of said ribs of said second spar, wherein said first spar and said second spar each has an elongated dimension and said base has a width normal to said elongated dimension, said width decreasing in a step-wise fashion along said elongated dimension of said first and said second spars from said spar root end to said spar tip end, said first and said second spars being composed of a spar reinforcing fiber and a spar thermoset resin, each said rib of said first spar and said second spar has a depth, said depth of each said rib decreasing along said elongated dimension of said first and said second spars from said root end to said tip end wherein said shear web comprises:iv. a first shear web skin;v. a second shear web skin;vi. a shear web core, said first and said second shear web skins being strong compared to said shear web core, said first and said second shear web skins being attached to opposing sides of said shear web core, said shear web having a first shear web edge and a second shear web edge;vii. a first connector and a second connector, said first and said second connectors comprising a connector thermoset resin and a connector reinforcing fiber, said first connectors being bonded to a one of said first and said second shear web edges and to one said rib of said first spar, said second connector being bonded to the other of said first and said second shear web edges and to one said rib of said second spar;viii. a plurality of pin members, a plurality of holes being defined by first and said second connectors and said ribs to which said first and said second connectors are bonded, each of said pin members being disposed within a one of said holes. 17. The wind turbine of claim 16 wherein said first composite skin and said second composite skin each defines a trailing edge portion, said trailing edge portions of said first and said second composite skins having a releasable attachment joining one of said first and said second composite skins to the other to define said rotor blade trailing edge. 18. The wind turbine of claim 17 wherein said releasable attachment of said trailing edge portions further comprises: a mechanical lock, said mechanical lock having a male portion and a female portion, said male portion being bonded to a one of said first and said second composite skins, said female portion being bonded to the other of said first and said second composite skins, said male portion being releasably retained by said female portion. 19. A wind turbine, the wind turbine comprising: a. a tower;b. an electrical generator, said electrical generator being supported above a ground by said tower;c. a rotor blade, said rotor blade having an axis of rotation, said tower supporting said rotor blade above said ground, said rotor blade being operably connected to said electrical generator, said rotor blade defining a leading edge, a trailing edge, a rotor blade root, a rotor blade tip, a chord and a span, said rotor blade further comprising: i. a first composite skin and a second composite skin, each of said first and said second composite skins having a composite skin root end defining said rotor blade root and a composite skin tip end defining said rotor blade tip;ii. a first spar and a second spar, said first and said second spars being elongated, each said first and said second spar having a spar base and a plurality of elongated ribs attached to and generally normal to said spar base, each said first and said second spar having a spar root end and a spar tip end, said first spar being bonded to said inside surface of said first composite skin, said second spar being bonded to said inside surface of said second composite skin, said spar root end of said first and said second spars being located proximal to said rotor blade root, said spar tip end of said first and said second spars being located proximal to said rotor blade tip;iii. at least one shear web, said shear web each having a first shear web edge and an opposing second shear web edge, said first shear web edge being attached to a one of said ribs of said first spar, said second shear web edge being attached to a one of said ribs of said second spar, wherein said first spar and said second spar each has an elongated dimension and said base has a width normal to said elongated dimension, said width decreasing in a step-wise fashion along said elongated dimension of said first and said second spars from said spar root end to said spar tip end, said first and said second spars being composed of a spar reinforcing fiber and a spar thermoset resin, each said rib of said first spar and said second spar has a depth, said depth of each said rib decreasing along said elongated dimension of said first and said second spars from said root end to said tip end;iv. a leading edge skin, said leading edge skin extending from said rotor blade root to said rotor blade tip, said leading edge skin defining said leading edge, said leading edge skin having a releasable attachment to each of said first skin and to said second skin, said releasable attachment between said leading edge skin and said first and said second composite skins comprising:v. a composite skin hinge, said composite skin hinge extending said span of the rotor blade, said composite skin hinge being bonded to said first composite skin or said second composite skin; andvi. a leading edge skin hinge, said leading edge skin hinge being attached to said leading edge skin, said leading edge skin hinge matably engaging said composite skin hinge; andvii. a retaining pin, said retaining pin engaging said composite skin hinge and said leading edge skin hinge, said retaining pin holding said leading edge skin hinge and said composite skin hinge in engagement. 20. A method for making a rotor blade for a wind turbine, the rotor blade having a rotor blade root and a rotor blade tip, the method comprising: a. creating a first and a second composite skin, said first and second composite skins comprising a skin reinforcing fiber and a skin resin, each of said first and second composite skins having an inside surface, each of said first and said second composite skins defining a leading edge portion and a trailing edge portion, each of said first and said second composite skins having a longitudinal dimension extending from the rotor blade root to the rotor blade tip;b. pultruding a first spar and a second spar by pulling a mixture of a spar thermoset resin and a spar fiber through a pultrusion die, said pultrusion die being configured so that each said spar defines a spar base and a plurality of elongated ribs integral to and generally normal to said spar base, each of said spar bases of said first and said second spars being elongated and having an elongated dimension, each of said ribs extending in said elongated dimension;c. attaching said spar base of a one of said spars and said inside surface of said first rotor blade skin, said elongated dimension of said one of said spars being parallel to said longitudinal dimension of said first rotor blade skin;d. attaching said spar base of the other of said spars and said inside surface of said second rotor blade skin, said elongated dimension of said other of said spars being parallel to said longitudinal dimension of said second rotor blade skin;e. attaching at least one of said ribs of said first spar to a corresponding one of said ribs of said second spar at least one of said ribs of said first spar not being attached to a one of said ribs of said second spar at a location along said first spar or said second spar;f. releasably attaching said trailing edge portions of said first and said second rotor blade skins one to the other.
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