Wind turbine rotor blade components and methods of making same
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
F04D-029/38
B63H-001/26
출원번호
US-0585339
(2012-08-14)
등록번호
US-8540491
(2013-09-24)
발명자
/ 주소
Gruhn, Joel D.
Franklin, Ethan
Narasimhan, Kameshwaran
출원인 / 주소
Neptco, Inc.
대리인 / 주소
Mintz Levin Cohn Ferris Glovsky and Popeo, P.C.
인용정보
피인용 횟수 :
14인용 특허 :
2
초록▼
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
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.
대표청구항▼
1. A structural element for a wind turbine blade comprising: a composite beam configured to extend along at least a portion of an airfoil of the wind turbine blade;the composite beam including two or more preform layers, each preform layer including multiple elongate strength rods arranged longitudi
1. A structural element for a wind turbine blade comprising: a composite beam configured to extend along at least a portion of an airfoil of the wind turbine blade;the composite beam including two or more preform layers, each preform layer including multiple elongate strength rods arranged longitudinally relative to one another in a single layer, each strength rod being disposed adjacent to 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 and the fixed distance permits the flow of liquid bonding resin between adjacent strength rods of a preform layer to its joined carrier layer;wherein the carrier layer of at least one preform layer includes one or more permeable materials suitable to facilitate permeation and penetration to permit flow of liquid bonding resin between stacked preform layers;each preform layer being stacked with one or more other preform layers; andwherein multiple stacked preform layers define a transverse width and a thickness of the composite beam. 2. The structural element of claim 1, further comprising one or more layers of at least one of a fibrous woven material and a fibrous non-woven material stacked with the one or more preform layers. 3. The structural element of claim 2, wherein the fibrous material is selected from one or more of: glass fabrics, meshes, fibers, yarns and/or rovings; carbon fabrics, meshes, fibers, yarns and/or rovings; graphite fabrics, meshes, fibers, yarns and/or rovings; basalt fabrics, meshes, fibers, yarns and/or rovings; and ceramic fabrics, meshes, fibers, yarns and/or rovings. 4. The structural element of claim 1 wherein the multiple stacked or layered preform layers are fixed in a liquid bonding resin which is solidified to define the composite beam. 5. The structural element of claim 1, wherein the ends of each preform layer correspond to stations of the preform layer and wherein the multiple stacked preform layers define one or more different lengths to define the composite beam having a tapering thickness. 6. The structural element of claim 1, wherein at least one end portion of one or more preform layers terminates in a tapered end zone, the tapering being at a selected rate of taper. 7. The structural element of claim 1, including an absence of material between each strength rod, the absence of material permitting substantially unimpeded flow of liquid bonding resin between adjacent strength members. 8. The structural element of claim 1, wherein the carrier layer includes at least one of: a nonwoven material and a woven material. 9. The structural element of claim 4, wherein an adhesive compatible with the liquid bonding resin joins the carrier layer and the multiple strength rods. 10. The structural element of claim 8, wherein the at least one of a nonwoven material and a woven material is selected for its wettability and material compatibility. 11. The structural element of claim 10, wherein one of the carrier layer and the strength rods includes at least one layer of adhesive to join the strength rods to the carrier layer. 12. The structural element of claim 8, wherein the carrier layer of a given preform layer comprises at least one of a nonwoven material and a woven material having one or more of substantially unidirectional: multiple fibers, multiple yarns and multiple rovings disposed at a substantially transverse orientation relative to the longitudinal axis of the strength rods. 13. The structural element of claim 1, wherein two or more preform layers are stacked such that at least one strength rod of at least one preform layer is disposed in substantial longitudinal alignment with at least one strength rod of at least another preform layer disposed above or below the one preform layer, the spacing between preform layers and adjacent strength rods forming passages to permit the flow of liquid bonding resin. 14. The structural element of claim 1, wherein two or more preform layers are stacked and wherein at least one of the strength rods in one preform layer is disposed in substantial longitudinal alignment with at least a portion of the space between adjacent strength rods of another preform layer. 15. The structural element of claim 1, wherein two or more preform layers are stacked, and wherein the strength rods of one preform layer are disposed randomly with respect to the strength rods of another preform layer but aligned along their longitudinal axes. 16. The structural element of claim 1, wherein the structural element comprises one or more of a spar cap, an I-beam, a shear web and other structural blade components of the wind turbine blade. 17. The structural element of claim 4 wherein the liquid bonding resin is solidified using one or more of: ambient temperature curing, chemical curing, ultraviolet curing, electron beam curing, and curing by the application of heat and pressure.
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