A wind turbine blade comprising an aerodynamic blade shell with recess and pre-manufactured spar cap

Abstract

A wind turbine blade has a load carrying structure including at least a first spar cap and an aerodynamic shell having an outer surface forming at least part of an exterior surface of the wind turbine blade and an inner surface. The aerodynamic shell includes a first recess at the inner surface of the blade shell with a first thickened part at a first side of the first recess and a second thickened part at a second side of the first recess. The first recess is tapered towards the first side of the recess and tapered towards the second side of the recess, and the first spar cap is arranged in the first recess of the aerodynamic shell. The first spar cap is tapered towards a first side of the spar cap and further is tapered towards a second side of the spar cap.

Description

TECHNICAL FIELD[0001]The present invention relates to a method of manufacturing a wind turbine blade and intermediate products of a wind turbine blade. The invention further relates to a wind turbine blade and intermediate products of the wind turbine blade.BACKGROUND[0002]Wind turbine blades are often manufactured according to one of two constructional designs, namely a design where a thin aerodynamic shell is glued onto a spar beam, or a design where spar caps, also called main laminates, are integrated into the aerodynamic shell.[0003]In the first design, the spar beam constitutes the load bearing structure of the blade. The spar beam as well as the aerodynamic shell or shell parts are manufactured separately. The aerodynamic shell is often manufactured as two shell parts, typically as a pressure side shell part and a suction side shell part. The two shell parts are glued or otherwise connected to the spar beam and are further glued to each other along a leading edge and trailing...

AI Technical Summary

Benefits of technology

[0068]This manufacturing method provides a simple way of forming the aerodynamic shell with a recess at the correct position and for connecting the spar cap at the correct position to the blade shell. Further, the insert ensures that fibre material and sandwich core material does not slide down from the sides of the mould and cause

Problems solved by technology

Ensuring a complete distribution of the polymer in the entire mould cavity is, however, often difficult, and accordingly this often results in so-called dry spots, i.e. areas with fibre material not being sufficiently impregnated with resin.

Thus dry spots are areas where the fibre material is not impregnated, and where there can be air pockets, which are difficult or impossible to remove by controlling the vacuum pressure and a possible overpressure at the inlet side.

This is a time-consuming and tiresome process.

This is not desirable, especially not when the polymer has not hardened, as it can result in deformations in the inserted fibre materia

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