Wind turbine rotor blade components and methods of making same

Patent metadata

Field	Value
Publication number	US-9394882-B2
Application number	US-201414530071-A
Country	US
Kind code	B2
Filing date	Oct 31, 2014
Priority date	Jan 14, 2010
Publication date	Jul 19, 2016
Grant date	Jul 19, 2016

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.

First claim

What is claimed is:

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.

Assignees

• Neptco Inc
• Senvion Gmbh

Inventors

• Gruhn Joel D
• Franklin Ethan
• Narasimhan Kameshwaran

Classifications

• Y10T29/49337

  Composite blade · CPC title

• Y10T29/49787

  Obtaining plural composite product pieces from preassembled workpieces · CPC title

• Y10T29/4979

  Breaking through weakened portion · CPC title

• Y10T29/49632

  Metal reinforcement member for nonmetallic, e.g., concrete, structural element · CPC title

• B23P15/04

  turbine or like blades from several pieces · CPC title