초록 ▼

An airfoil structure including a plurality of molded monolithic members that extend in a side-by-side manner along the spanwise direction of the airfoil structure. Each molded monolithic member is realized from continuous material that is molded to form a corrugated portion with top and bottom flang

An airfoil structure including a plurality of molded monolithic members that extend in a side-by-side manner along the spanwise direction of the airfoil structure. Each molded monolithic member is realized from continuous material that is molded to form a corrugated portion with top and bottom flange portions extending from the corrugated portion. As a result of the molding operation, the corrugated portion is integrally formed with and structurally joined to the top and bottom flange portions. The top flange portions of the side-by-side arrangement of molded monolithic members define a portion of the top surface of the airfoil structure. The bottom flange portions of the side-by-side arrangement of molded monolithic members define a portion of the bottom surface of the airfoil section. The corrugated portions of the side-by-side arrangement of monolithic members define internal support structures (preferably closed-cell cores) extending along the spanwise direction of the airfoil structure. The side-by-side arrangement of monolithic members structurally integrates portions of the top skin and bottom skin to support structures that extend between such top and bottom surface portions. Such structural integration provides enhanced structural resistance to torsional loading of the airfoil section due to the fact that such loads are resisted by the continuous material that makes up the both top and bottom surfaces as well as the support structures extending therebetween.

대표청구항 ▼

1. An apparatus comprising: an airfoil structure including a root, a tip, and a span extending along a spanwise direction between said root and said tip, said span having a top surface opposite a bottom surface, wherein at least part of said span is defined by a plurality of molded monolithic member

1. An apparatus comprising: an airfoil structure including a root, a tip, and a span extending along a spanwise direction between said root and said tip, said span having a top surface opposite a bottom surface, wherein at least part of said span is defined by a plurality of molded monolithic members that extend in a side-by-side manner along the spanwise direction, each molded monolithic member including a corrugated portion with a top flange portion and a bottom flange portion extending from the corrugated portion, said top flange portions of adjacent molded monolithic members overlap one another to define said portion of the top surface; and said bottom flange portions of adjacent molded monolithic members overlap one another to define said portion of the bottom surface, said corrugated portion integrally formed with and joined to said top flange portion and said bottom flange portion, the overlapping top and bottom flange portions have a stepped interface to aid in side-by-side alignment of the plurality of molded monolithic members and provide four distinct planes by which to glue, bond or otherwise affix in sheer the plurality of molded monolithic members. 2. An apparatus according to claim 1, wherein: said corrugated portions of said molded monolithic members provide structural resistance to shear forces acting on the top and the bottom surfaces of said airfoil structure. 3. An apparatus according to claim 2, wherein: said corrugated portions of said molded monolithic members provide structural resistance to bending-moment forces, compression forces, and torsional forces acting on said airfoil structure. 4. An apparatus according to claim 1, wherein: said corrugated portions of said molded monolithic members define internal closed-cell cores extending along the spanwise direction of said airfoil structure. 5. An apparatus according to claim 4, wherein: said internal closed-cell cores provide structural resistance to shear forces acting on the top and the bottom surfaces of the airfoil. 6. An apparatus according to claim 5, wherein: said internal closed-cell cores provide structural resistance to bending-moment forces, compression forces, and torsional forces acting on said airfoil structure. 7. An apparatus according to claim 1, further comprising: at least one non-corrugated sheet disposed between the corrugated portions of adjacent molded monolithic members along the spanwise direction of said airfoil structure. 8. An apparatus according to claim 7, wherein: the corrugated portions of adjacent molded monolithic members and at least one non-corrugated sheet disposed therebetween define internal closed-cell cores extending along the spanwise direction of said airfoil structure. 9. An apparatus according to claim 8, wherein: the at least one non-corrugated sheet provides structural resistance primarily to bending-moment forces and compressive forces acting on said airfoil structure. 10. An apparatus according to claim 1, wherein: the dimensions of said plurality of molded monolithic members vary across the spanwise direction to provide a desired profile along the spanwise direction of said airfoil structure. 11. An apparatus according to claim 1, wherein: said plurality of molded monolithic members are adapted to be secured together in a nested manner to provide a desired profile along the spanwise direction of said airfoil structure. 12. An apparatus according to claim 11, wherein: said desired profile substantially lies in a flat plane along the spanwise direction of said airfoil structure. 13. An apparatus according to claim 11, wherein: said desired profile twists clockwise or counterclockwise along the spanwise direction of said airfoil structure in order to vary angle of incidence of said airfoil structure along the spanwise direction. 14. An apparatus according to claim 4, wherein: the corrugated portions of adjacent molded monolithic members are arranged in a staggered pattern to define said internal closed-cell cores. 15. An apparatus according to claim 14, wherein: said internal closed-cell cores are polygonal in shape. 16. An apparatus according to claim 14, wherein: said internal closed-cell cores are split in half by non-corrugated sheets disposed between corrugated portions of adjacent molded monolithic members. 17. An apparatus according to claim 1, wherein: said airfoil structure has a rounded leading edge and a tapered trailing edge. 18. An apparatus according to claim 17, wherein: a first group of said molded monolithic members each have top and bottom flanges that extend away from an underlying corrugated portion toward said trailing edge. 19. An apparatus according to claim 18, wherein: a plurality of said first group of molded monolithic members each has a set of flat surfaces facing said leading edge. 20. An apparatus according to claim 18, wherein: one of said first group of molded monolithic members has a rounded side that is covered by a cap to define said leading edge. 21. An apparatus according to claim 17, wherein: a second group of said molded monolithic members each have top and bottom flanges that extend away from an underlying corrugated portion toward said leading edge. 22. An apparatus according to claim 21, wherein: a plurality of said second group of molded monolithic members each has a set of flat surfaces facing said trailing edge. 23. An apparatus according to claim 21, wherein: one of said second group of molded monolithic members has a tapered side that is covered by a cap to define said trailing edge. 24. An apparatus according to claim 17, wherein: the airfoil structure includes at least one additional support member that extends centrally along the spanwise direction of said airfoil structure. 25. An apparatus according to claim 24, wherein: the additional support structure comprises a composite box spar. 26. An apparatus according to claim 24, wherein: the additional support member comprises at least one stringer. 27. An apparatus according to claim 24, wherein: said at least one additional support member provides a transition between first and second groups of molded monolithic members, wherein the top and bottom flanges of said first group of molded monolithic members extend away from an underlying corrugated portion toward said trailing edge, and wherein the top and bottom flanges of said second group of molded monolithic members extend away from an underlying corrugated portion toward said leading edge. 28. An apparatus according to claim 27, wherein: the top and bottom flange portions of the molded monolithic members of the first and second group that are disposed adjacent said at least one additional support member provide portions of the top surface and bottom surface that cover said least one additional support member. 29. An apparatus according to claim 1, wherein: said molded monolithic members are constructed from at least one metal. 30. An apparatus according to claim 29, wherein: said at least one metal is selected from the group consisting of aluminum, titanium, stainless steel, steel, and any combinations thereof. 31. An apparatus according to claim 1, wherein: said molded monolithic members are constructed from at least one polymer. 32. An apparatus according to claim 31, wherein: said at least one polymer is selected from the group consisting of polyester, vinylester, epoxy, urethane, and any combinations thereof. 33. An apparatus according to claim 1, wherein: said molded monolithic members are realized from at least one composite material. 34. An apparatus according to claim 33, wherein: said composite material comprises a fiber reinforcement material and a resin matrix material. 35. An apparatus according to claim 34, wherein: the fiber reinforcement material comprises a multilayer fabric with multiple fabric layers having varying fiber orientations. 36. An apparatus according to claim 35, wherein: said multilayer fabric comprises three fabric layers with unidirectional fibers oriented at 45°, 90°, −45°, respectively, relative to a longitudinal axis of said multilayer fabric. 37. An apparatus according to claim 34, wherein: the fiber reinforcement material comprises fibers of a material selected from the group consisting of glass (such as E-glass or S-glass), nylon, polyamides (typically referred to as PA fiber), aromatic polyamides (typically referred to as aramids), Kevlar®, polyethylene (such as ultra-high molecular weight polyethylene, high-modulus polyethylene, and high-performance polyethylene), polyethylene terephthalate (typically referred to as PET fiber), steel, titanium, carbon, basalt, and any combinations thereof. 38. An apparatus according to claim 34, wherein: the resin matrix material is selected from the group consisting of polyester resins, vinyl ester resins, epoxy resins, phenolic resins, polyimide resins, polyamide resins, polypropylene resins, PEEK resins, methacrylate resins, and any combinations thereof. 39. An apparatus according to claim 7, wherein: said at least one non-corrugated sheet is realized from a composite material. 40. An apparatus according to claim 39, wherein: said composite material includes a fiber reinforcement material and a resin matrix material. 41. An apparatus according to claim 40, wherein: the fiber reinforcement material comprises a multilayer fabric with multiple fabric layers having varying fiber orientations. 42. An apparatus according to claim 41, wherein: said multilayer fabric comprises three fabric layers with unidirectional fibers oriented at 45°, 90°, −45°, respectively, relative to a longitudinal axis of said multilayer fabric. 43. An apparatus according to claim 40, wherein: the fiber reinforcement material comprises fibers of a material selected from the group consisting of glass (such as E-glass or S-glass), nylon, polyamides (typically referred to as PA fiber), aromatic polyamides (typically referred to as aramids), Kevlar®, polyethylene (such as ultra-high molecular weight polyethylene, high-modulus polyethylene, and high-performance polyethylene), polyethylene terephthalate (typically referred to as PET fiber), steel, titanium, carbon, basalt, and any combinations thereof. 44. An apparatus according to claim 40, wherein: the resin matrix material is selected from the group consisting of polyester resins, vinyl ester resins, epoxy resins, phenolic resins, polyimide resins, polyamide resins, polypropylene resins, PEEK resins, methacrylate resins, and any combinations thereof. 45. An apparatus according to claim 1, wherein: said plurality of molded monolithic members are bonded together by a resin material. 46. An apparatus according to claim 45, wherein: the resin material is selected from the group consisting of polyester resins, vinyl ester resins, epoxy resins, phenolic resins, polyimide resins, polyamide resins, polypropylene resins, PEEK resins, methacrylate resins, and any combinations thereof. 47. An apparatus according to claim 1, wherein: said plurality of molded monolithic members are bonded together by welding or brazing. 48. An apparatus according to claim 1, wherein: said plurality of molded monolith members are secured together by mechanical fasteners such as rivets and machine screws. 49. An apparatus according to claim 1, wherein: the top and bottom surfaces of the airfoil structure include a coating, film or skin applied to said top and bottom flange portions of said plurality of molded monolithic members. 50. An apparatus according to claim 49, wherein: said coating is reflective to reduce heating of said airfoil structure resulting from incident sunlight. 51. An apparatus according to claim 49, wherein: said coating limits migration of moisture into the internal elements of the airfoil structure. 52. An apparatus according to claim 49, wherein: said skin adds additional structural strength to and between said plurality of molded monolithic members. 53. An apparatus according to claim 1, wherein: the airfoil structure is part of an aircraft wing or propeller blade. 54. An apparatus according to claim 53, further comprising: openings through the corrugated portions of said plurality of molded monolithic members to provide a passageway therethrough (e.g., for wiring, hydraulic lines, control rods, fuel lines, fluid lines, venting, reinforcement rods, etc.). 55. An apparatus according to claim 1, wherein: the airfoil structure is part of a horizontal-axis-type wind turbine blade. 56. An apparatus according to claim 55, further comprising: a laminate structure of reinforcement members extending from the root of said airfoil structure; andmounting means for mounting the blade to a rotatable wind turbine hub, the mounting means including a plurality of mechanical fasteners that interface to said laminate structure. 57. An apparatus according to claim 1, wherein: the airfoil structure comprises a vertical-axis-type wind turbine blade. 58. An apparatus according to claim 55, further comprising: reinforcement material injected into internal voids formed by said plurality of molded monolithic members that define the span of said blade; andmounting means for mounting the span of said blade to a rotatable structure, said mounting means including at least one mechanical fastener that interfaces to said reinforcement material. 59. An apparatus according to claim 58, wherein: said mounting means includes a top mount interface including at least one mechanical fastener that interfaces to reinforcement material disposed locally in a top portion of the span of said blade, anda bottom mount interface including at least one mechanical fastener that interfaces to reinforcement material disposed locally in a bottom portion of the span of said blade.