A carrier plate for a preform manufacturing structure for producing a preform element of a wind turbine blade and a mould structure for producing a preform element of a wind turbine blade

Abstract

A carrier plate for a preform manufacturing structure for producing a preform element of a wind turbine blade and a mould structure for producing a preform element of a wind turbine blade. A carrier plate for a preform manufacturing structure for producing a preform element of a wind turbine blade is adapted to receive a mould element (23) with a preform build material (24) on a receiving surface (4) or to receive the preform build material directly on the receiving surface (4), wherein the carrier plate (1) has a rectangular shape with a longer longitudinal axis and a shorter transverse axis, wherein the carrier plate (1) is flexible around the longitudinal axis but reinforced against bending around the transverse axis and stretchable along the transverse axis but rigid along the longitudinal axis.

Description

Technical Field

[0001] This invention relates to a support plate for a preform manufacturing structure for producing preformed components of wind turbine blades. Background Technology

[0002] As is well known, wind turbines typically consist of multiple turbine blades attached to a hub. The blades interact with the wind, causing the hub to rotate. A generator is coupled to the hub and driven by the rotating hub. Modern turbine blades are enormous in length and width. Therefore, their manufacture is difficult due to the handling of large components. One technique for producing such large blades uses preforms, which are pre-formed smaller blade parts used to build the corresponding blade shell. These preforms are arranged and aligned according to the overall geometry required by the blade and are ultimately joined together, embedded accordingly in fiber pads and resin, etc., for use in manufacturing the final large blade or blade part.

[0003] Each preform is pre-formed in a specific mold, typically having a slightly curved geometry with a length of, for example, 10-12 m and a width of, for example, 3-5 m. The mold includes corresponding forming sections in which preformed building materials, such as fiber pads and adhesives, and optionally core elements are arranged. These materials are fixed in the corresponding mold sections by applying a vacuum, the mold sections having defined geometries corresponding to the required blade geometry, and thus, in most cases, tray-like. For this fixation, the preformed building materials are covered, for example, with foil, so that a vacuum can be applied to the space between the foil and the mold section, in which the building materials are arranged. Heat is then applied to the building materials to melt a locally provided adhesive for locally fixing the fiber pads and core elements, etc., by gluing them to an adhesive matrix provided by the molten adhesive. After this heating operation, the preform needs to be cooled to room temperature, after which it is sufficiently stable to be handled by crane equipment or any other similar processing or lifting device.

[0004] This method of producing preforms is quite cumbersome. The molds used to produce preforms are very complex in their setup, especially because each mold requires a heating and cooling system. This makes the molds very expensive, given the large number of individual molds needed, as typically at least 20 or more preforms are required to produce blades or blade components. Furthermore, since the corresponding mold geometry is designed for the corresponding geometry of the preform, significant rework of the molds is required when the preform geometry needs to be changed, necessitating adjustments to the heating and cooling equipment.

[0005] Furthermore, since both heating and cooling processes occur while the preformed building material or corresponding thermoformed part is arranged in the mold, the mold is occupied. Because the heating and cooling processes take a considerable amount of time, the entire mold becomes clogged during these lengthy procedures, resulting in extremely low productivity. This is further amplified by the inability to preheat the mold. Temperature treatment must begin at room temperature because all building material must be individually arranged in the mold before vacuum curing can begin. Additionally, it is necessary to cool the thermoformed part to room temperature to ensure its stability when processing it using lifting equipment. Moreover, the time the corresponding mold is occupied can be extended, because when no storage capacity is provided, sometimes the preformed part is not immediately removed after cooling but remains in the mold for a certain period.

[0006] As an alternative technique, a flexible plate-shaped mold element can be arranged on a corresponding shape-defined surface of a receiving section of the mold, such as a tray. The thin plate-shaped mold element, due to its flexibility, is adapted to change its shape and conform to the geometry of, for example, the tray-shaped receiving section, allowing the flexible plate to smoothly cover the receiving section. This allows pre-formed building material to be arranged on the plate-shaped mold element, where it can then be covered with the aforementioned vacuum foil and vacuum-fixed. This vacuum fixing also fixes the complete arrangement, such as the tray-shaped geometry, comprising the shape-adapted flexible plate-shaped mold element, the building material, and the vacuum foil, enabling the subsequent handling of arrangements with relatively rigid and three-dimensional shapes. The plate-shaped mold element with the vacuum-fixed building material can then be removed from the receiving section and, for example, arranged in a conveyor that transports the mold element with the building material to a separate heating device, such as an oven, where it is heated and subsequently cooled in ambient air, or transferred to a cooling device for final cooling. In this configuration, the mold is used only to arrange the build material onto the plate-shaped mold element, while the heating and cooling processes are performed elsewhere. Therefore, the mold can be immediately reused to prepare another preformed element simply by arranging a new flexible plate-shaped mold element on the receiving section and then arranging new build material again.

[0007] As mentioned, the preformed building material is arranged on a plate-shaped mold element and vacuum-fixed. This fixation provides a rigid setup to maintain its shape. However, stabilizing this arrangement is advantageous for further processing. Summary of the Invention

[0008] Therefore, one objective is to provide an improved apparatus for manufacturing preform structures that allows for the stable handling of fixed preform building materials.

[0009] To achieve this objective, the present invention provides a support plate for manufacturing a preformed component for producing preformed elements for wind turbine blades. The support plate is adapted to receive a mold element having preformed building material on a receiving surface, or directly on the receiving surface. The support plate has a rectangular shape with a longer longitudinal axis and a shorter transverse axis. The support plate is flexible about the longitudinal axis but reinforced about the transverse axis to resist bending, and is stretchable along the transverse axis but rigid along the longitudinal axis.

[0010] The carrier plate of the present invention, being a single-piece plate, possesses specified flexibility and tensile strength, which allows for shape adaptation and, on the other hand, allows for changes in its dimensions. The carrier plate is flexible and therefore bendable about its longitudinal axis, which is a longer axis due to the rectangular shape. This flexibility, or corresponding bendability, allows the carrier plate to adapt, for example, to the geometry of a loaded mold element with fixed preformed building material, the carrier plate having a convex or tray-like form, for example, due to its shape adaptation in the mold receiving section, such that the carrier plate perfectly supports the mold element with vacuum-fixed building material over the entire contact area. Thus, the carrier plate can perfectly adapt its geometry to the geometry of the mold element to be carried. This, for example, allows the carrier plate to be used as part of a conveying device onto or within which, after vacuum fixing, a plate-shaped mold element with vacuum-fixed building material is loaded. The conveying device, for example, comprises four or more of these carrier plates, each adapted to receive one loaded mold element. All mold elements are perfectly supported on their respective carrier plates, thus ensuring safe transport and further processing.

[0011] If the support plate is used as part of the conveying device, the lateral stretchability is also highly advantageous because it allows for changes in the lateral length of the support plate. Mold elements with vacuum-fixed preformed building materials are very heavy, weighing several hundred kilograms, as the building material itself typically weighs several hundred kilograms. Therefore, when the support plate is arranged in the conveying device, it needs to withstand very heavy loads, while simultaneously ensuring that no force or load is applied to the mold element when it is loaded onto the support plate, which would significantly alter the geometry of the mold element or the corresponding vacuum-fixed preformed building material. This is determined by the lateral stretchability, which allows the support plate, secured to the conveying device by its longitudinal sides or edges, to elongate when the heavy mold element is placed on it. Thus, the support plate can be stretched, for example, by its side regions, which follow to the longitudinal edges, along which the support plate is secured to the conveying device due to the weight of the mold element, while the area of ​​the support plate on which the mold element is placed retains its shape. This confirms that no significant force or load is applied from the support plate to the mold element, since the support plate is load-sensitive due to its tensile properties in the transverse direction and can be adapted to its geometry again.

[0012] As mentioned, the support plate can be used as part of a conveying device and to receive the loaded mold element. It can also be used as a support device for further carrying the loaded article through further processing steps, such as heating or cooling steps, where the loaded article remains on the support plate. Furthermore, the support plate can also be used as part of the mold itself. It can be directly arranged on the corresponding receiving section of the mold, which defines the overall shape the preform should ultimately have. Due to the flexibility or elasticity of the support element, the support plate can easily conform to the three-dimensional geometry of the receiving section or a corresponding tray-like form when it can be bent about its longitudinal axis. A sheet-like mold element can now be arranged on the shape-adapted support plate, and then the preformed building material is arranged on the mold element and finally vacuum-fixed. Thereafter, the support plate, together with the sheet-like mold element with the vacuum-fixed building material, is removed from the receiving section of the mold and transferred, for example, to a conveying device, where the support plate is fixed at a corresponding fixing device and its shape can be changed, especially stretched, to avoid any undesirable forces or loads applied to the fixed building material, as mentioned above.

[0013] In an alternative where separate plate-shaped mold elements are arranged on a support plate disposed in the receiving section, pre-formed building materials, such as fiber pads, core elements, and adhesives, can be directly disposed on the support plate. In this case, the support plate has a dual function: firstly, it functions as a building material receiving and shape-defining device, and secondly, it functions as a device for carrying the final vacuum-fixed building material through subsequent processes. Furthermore, in this case, when the building material is vacuum-fixed, the support plate is also removed from the shape-defining recess of the receiving section and transferred to the conveying device, where the support plate re-engages with the corresponding fixing elements and can be reshaped again, especially stretched, to avoid any undesirable loads applied to the vacuum-fixed building material.

[0014] All these functions of the support plate are achieved by the specified flexibility and tensile strength. As mentioned, the support plate is flexible and can bend about its longitudinal axis, while it is reinforced to resist significant bending movement about its transverse axis. This determines that only some bending movement about the longitudinal axis is possible, but not about the transverse axis at a right angle. Furthermore, tensile strength is achieved only in the transverse direction, while the support plate is completely rigid along the longitudinal axis and is by no means tensile.

[0015] As mentioned, the support plate is a one-piece plate made of polymer or metal. As a polymer, any polymer exhibiting the corresponding mechanical properties and, in particular, heat resistance can be used, since, as mentioned, the pre-formed building material is heated in an oven to melt the binder, typically at a temperature between 60-90°C. An example of a usable polymer is polypropylene, but other polymers, as well as resin-based fibrous materials, can also be used. Alternatively, the one-piece support plate can also be made of metal, such as aluminum or steel or any suitable metal alloy. Preferably, aluminum is used because it is a lightweight material, preventing the support plate itself from becoming too heavy. Aluminum also has good thermal conductivity, which is advantageous when arranging the support plate in a heating device, such as an oven, to heat the building material.

[0016] In addition, flexible mold elements can also be made of metal with a polymer coating on at least one side receiving the preformed building material or mold element. While providing flexibility and tensile strength, overall stability is provided by the metal sheet, while the polymer coating allows for adjustment of surface properties. For example, a polymer can be used that does not adhere to or bind to the molten binder, allowing the final preform to be easily removed from the support plate when it is built directly onto the support plate.

[0017] The flexible mold element itself preferably has a thickness of 0.1-10 mm, more preferably 0.5-5 mm. Preferably, the support plate is as thin as possible while providing the required mechanical properties as well as the specified flexibility and tensile strength. If metal is used as the plate material, the thickness can be even smaller, for example, between 0.1-1.00 mm, because metal itself has excellent mechanical properties. If a polymer like polypropylene is used, the thickness can be larger.

[0018] As mentioned, a central feature is the stretchability of the plate in the transverse direction. Preferably, this stretchability is not achieved based on material properties, which would be possible if a sufficiently elastic polymer material were used, where such inherent stretchability is not provided for metal plates. Instead, the support plate of the present invention possesses its stretchability solely due to the mechanical or geometric means formed or shaped at the plate. The support plate is provided with specific geometric stretching segments formed directly at the one-piece support plate, which change their geometry when a corresponding tensile force is applied. These stretching segments also have spring-like properties. This means that when a force is applied, they stretch, but when the load is no longer applied, they relax again, causing the support plate to retract to its unloaded form. Viewed in the transverse direction, several such stretching segments or mechanical geometries are provided such that there are designated portions or regions where stretching can occur, while in the region between two stretching segments, no stretching is provided even when a load is applied. Of course, these stretching segments extend along the entire length of the support plate, thereby allowing the support plate to stretch and retract uniformly.

[0019] In one particular embodiment, the support plate is formed with one or more tension sections having a U-shaped profile open to the receiving surface and extending along a longitudinal axis. These tension sections have a specific U-shaped form that allows adjacent plate sections to move apart, thereby opening the U-shaped bending section and generating a retraction elasticity. The U-shape may vary in size; a larger U-shaped geometry will be more elastic than a smaller U-shaped geometry, thus also allowing for changes in overall elasticity by altering the dimensions of the U-shaped geometry. When no longer under load, adjacent plate sections retract again due to the retraction elasticity of the previously opened U-shaped tension sections. Significant tension can be achieved by providing multiple such tension sections, all extending parallel in the longitudinal direction and, for example, uniformly distributed when viewed in the transverse direction, or arranged at different distances when viewed in the transverse direction.

[0020] Preferably, the stretching section has a horseshoe-shaped cross-section, which may also be referred to as a teardrop-shaped cross-section.

[0021] As mentioned, it is preferable to provide a plurality of stretching segments that are equidistant when viewed laterally. This embodiment establishes a uniform stretchability. In an alternative, the plurality of stretching segments may be arranged at smaller distances in at least one segment compared to at least one other segment. In this embodiment, the distance between stretching segments in one region is less than the distance in another region. Therefore, the density of stretching segments in the first region is higher than the density in other regions. This establishes that the stretchability in the first region is significantly higher than that in the second region. For example, the density of stretching segments may be even higher in the two longitudinal side regions, for example, two or three times that in the central region. This establishes that the edge regions, in particular, are significantly stretchable, and these regions are generally not covered by preformed building material or plate-shaped mold elements loaded with preformed building material. Thus, significant stretching in the edge regions is achieved, which is very advantageous when the support plate is arranged, for example, in a conveyor, such that it can be stretched in the edge regions while the central region with building material or corresponding mold elements retains its shape, for example, the shape received due to shape adaptation in the mold. Of course, other areas besides the edges of the support plate can also exhibit high elasticity, such as the center or middle area or the area adjacent to the rear or front edge of the preform.

[0022] As mentioned, the stretching section, or each stretching section, with a U-shaped profile is open to a receiving surface of the support plate, on which the loaded mold element or preformed building material is received. Preferably, a resilient sealing device is provided, which at least partially fills the stretching section or each stretching section and is flush with the receiving surface. This sealing device ensures a closed receiving surface, which allows for good support of the loaded mold element, or in particular ensures that the building material can be directly arranged on the closed receiving surface. Thus, the receiving surface is closed, and any building material, such as a fiber pad, could take on an undesirable form due to the open stretching section, which could be pressed into the open stretching section when vacuum fixing is achieved. The use of a resilient sealing device is advantageous because the resilient material readily follows any stretching movement, as mentioned, which opens the U-shaped stretching section.

[0023] In an alternative to at least partially filling the stretched section with a flush, resilient sealing device, an elastic sheet covering the stretched section can be provided to the receiving surface. In this embodiment, an elastic cover or layer is disposed on the receiving section, the cover or layer being sufficiently elastic to follow any stretching movement, as mentioned, that opens and closes the receiving section, and mold elements or building materials are disposed on the elastic cover or layer. Such an elastic layer or cover can be provided regardless of the material used to construct the carrier plate. It can be disposed on polymer carrier plates as well as metal carrier plates. The elastic sheet cover can be a rubber material or any other elastomeric polymer.

[0024] As mentioned, the support plate is flexible and therefore can bend about its longitudinal axis, but is significantly reinforced to resist any bending about its transverse axis by means of appropriate reinforcement devices. To achieve this reinforcement, one or more rod-shaped reinforcement elements are arranged in the tension section or each tension section. According to this embodiment, the tension section or each tension section having a U-shaped profile serves not only as a tension section with spring-like properties but also as a container for receiving the rod-shaped reinforcement elements. These rod-shaped reinforcement elements are simply arranged in the U-shaped tension section, which is then preferably closed by a corresponding elastic sealing device or by an elastic cap as mentioned above. The rod-shaped reinforcement elements perfectly reinforce the support plate to resist any undesirable bending, especially when a corresponding number of tension sections with corresponding rod-shaped reinforcement elements are provided.

[0025] As mentioned, the support plate can be used as part of a conveying device, on which the loaded mold elements are arranged, or when the support elements are arranged in the mold and the preformed building material is arranged directly on the support plate, or when a thin, flexible template is arranged on the support plate, the support plate can be loaded into the conveying device. To allow the support plate to be securely fixed in the conveying device, fixing elements are preferably located on the side of the plate extending along the longitudinal axis and are adapted to fix the support plate to a carrier, such as a conveying device like a frame, or a receiving section of the mold, to which the support plate is fixed. Therefore, when the support plate is arranged, for example, in a conveying device, it is fixed and suspended in the conveying device along its longitudinal plate side, thus extending, for example, in the side region.

[0026] The fixing element is preferably implemented in the form of a hook-shaped curved plate edge. Therefore, both longitudinal edges are hook-shaped curved, which allows the side edges to be suspended in the corresponding receiving part of, for example, a conveying device.

[0027] The present invention also relates to a mold structure for producing preformed elements for wind turbine blades, the mold structure comprising a mold carrier having a receiving section adapted to receive a transferable support plate as mentioned above. The mold structure is adapted to receive such a particular support plate arranged in a preferably convex or concave recess of the receiving section, such that the support plate conforms to the geometry. As mentioned, either a flexible plate-like mold element is arranged on the support plate, and then the building material is arranged on the mold element and vacuum-fixed, or the building material is arranged directly on the support plate. However, in this embodiment, the support plate is arranged at the mold carrier but remains transferable, allowing the support plate to be removed from the mold carrier after the building material has been arranged and vacuum-fixed, regardless of how this is accomplished.

[0028] A receiving segment with a three-dimensional receiving surface can be constructed from a receiving plate, with a carrier plate conforming its shape to the three-dimensional receiving surface. The receiving plate has a receiving container, which is tray-shaped and adapted to receive the carrier plate. The carrier plate is shaped to fit the tray shape by bending about its longitudinal axis. The receiving plates are preferably interchangeable, allowing various receiving plates to be fixed to mold carriers with different tray shapes, thus enabling the construction of various preform element geometries. However, they all have corresponding receiving containers into which the carrier plate is arranged, and these receiving containers are adapted to the tray-shaped container form.

[0029] If the support plate is provided with a corresponding U-shaped tension section extending to the underside or bottom side of the support plate, the receiving container is provided with one or more slots, each slot adapted to receive the tension section of the support plate. This ensures that the protruding tension section engages in the corresponding slot, so that the support plate is in a flat support on the receiving surface.

[0030] In an alternative embodiment using a receiving plate, the receiving section can be constructed from a grid comprising multiple rods extending longitudinally along the mold carrier. In this embodiment, instead of a flat arrangement over the entire contact area, only partial contact is provided between the underside or bottom side of the support plate and the grid rods. However, this embodiment also achieves very precise support and corresponding shape adaptability.

[0031] Preferably, in this embodiment, the cross-sectional shape of the grid can be variable to alter the cross-sectional shape of the support plate resting on the grid. Therefore, the grid is not a fixed three-dimensional rod arrangement but rather its shape is changeable, making it possible to alter the geometry of the support plate defined by the grid. Thus, this arrangement allows the mold itself to adapt to a new preform shape, which can then be constructed simply by changing the shape of the grid. Grid modification is not necessary because the grid form itself is changeable.

[0032] For example, this can be achieved by connecting rods to multiple cables extending laterally along the mold carrier, such that the degree of curvature of the grid profile can be changed by pulling or releasing the cables. Since the container shape typically achieved by the grid is convex or tray-shaped, the possibility of pulling or releasing the cables allows for changing the radius of the convex or tray-shaped receiving section. Therefore, simple radius adaptation is possible if needed. Because multiple such cable connections are arranged along the length of the grid, the shape and thus the radius can be locally adjusted at each of these cable locations, making it possible to change the radius from one grid end to another. The radius can be made smaller or larger simply by pulling or releasing the corresponding cable. Each cable can, of course, be fixed in its corresponding position.

[0033] If such a grid is used as a receiving section, the grid may be provided with one or more fixing elements for securing the support plate. These fixing elements allow the support plate to be securely fixed to the grid. Preferably, the fixing elements, or each fixing element, are clamps adapted to clamp the protruding tension sections of the support plate. For example, these clamps arranged in the area where the cable is located can be opened and closed. In the open state, the protruding tension section engages in the clamp, while the closed clamp securely fixes the tension section, especially when the tension section has a horseshoe-shaped profile. These clamps can be controlled simultaneously, for example, pneumatically, so that the overall fixation can be simultaneously achieved or released by means of appropriate control. These clamps are also adapted to pull the support plate toward the grid so that they determine a perfect form fit even when gravity alone is insufficient.

[0034] In addition, the mold structure is of course equipped with one or more vacuum devices. At least one vacuum device is necessary to apply a vacuum to a vacuum foil arranged on a plate-shaped mold element, if such a mold element is used, or directly on a support plate, if the building material is arranged directly on the support plate. Of course, when the loaded plate or the loaded support element is to be removed from the mold, the vacuum connection can be separated, while a vacuum is still provided for permanent fixation. Furthermore, if a flexible plate arranged on the support plate needs to be vacuum-suctioned against a receiving surface provided by the support plate to ensure a complete shape fit, a second vacuum device can be provided. In this case, the space between the mold element and the support plate needs to be evacuated. To accomplish this evacuation, the mold element can be provided with sealing elements extending along its four sides and sealing towards the support plate. Furthermore, when the support plate, together with the mold element, is to be removed from the mold and transferred to a conveyor, the vacuum connection can also be separated, while a vacuum is still maintained here. Attached Figure Description

[0035] Other objects and features of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings. However, the drawings are merely schematic diagrams designed for illustrative purposes only and do not limit the invention. The drawings show:

[0036] Figure 1 This is the main perspective view of the support plate.

[0037] Figure 2 It is observed along the longitudinal direction. Figure 1 A partial view of the bearing plate.

[0038] Figure 3 It is a schematic diagram demonstrating the tensile properties of the load-bearing plate.

[0039] Figure 4 This is a schematic diagram of a load-bearing plate viewed along the longitudinal direction. The load-bearing plate has multiple unevenly distributed tension sections.

[0040] Figure 5 yes Figure 4 An enlarged view of segment V.

[0041] Figure 6 This is a partial view taken along the longitudinal direction of the edge region of the support plate, showing the fixing elements of the support plate arranged at the support device of, for example, a conveying device.

[0042] Figure 7 This is a schematic diagram of a mold structure, including the mold itself and a conveyor system with multiple support plates.

[0043] Figure 8 This is another embodiment of a mold structure including a mold and a support plate arranged at the mold.

[0044] Figure 9 This is an enlarged view of the receiving section of a mold, which has a support plate arranged thereon.

[0045] Figure 10 This is another embodiment of a mold structure having a receiving section in the form of a grid.

[0046] Figure 11 This is an enlarged view of the fixing elements arranged at the grid to secure the support plate to the grid.

[0047] Figure 12 This is an enlarged view of the mold structure, showing the arrangement of preformed building materials on a transferable plate arranged on the mold, and...

[0048] Figure 13 It is a schematic diagram of the complete manufacturing structure, including multiple molds, a conveying device with multiple support plates, a heating device, and a cooling device. Detailed Implementation

[0049] Figure 1 A perspective schematic diagram of a support plate 1 is shown, which is used in a preform manufacturing structure for producing preformed components of wind turbine blades. The support plate 1 serves as a support device on which preformed building material is received directly or arranged on a transferable, flexible, plate-shaped mold element. The support plate 1 carries the building material throughout the entire manufacturing process, which either begins directly in the mold, where the support plate is arranged on the mold's receiving section, where the preformed building material is first arranged, or begins with the support plate arranged in a conveyor, where it receives a plate-shaped mold element with preformed building material, which is transferred directly from the mold onto the support plate 1.

[0050] The support plate 1 is made of a polymer, such as polypropylene, or of a metal, such as aluminum. As for the plate itself, it is a single-piece plate. It is made from a single large, rectangular polymer or metal sheet, which is accordingly shaped to achieve the appropriate geometry, particularly in the tension sections and fixing elements, as will be discussed later.

[0051] The support plate 1, or the corresponding polymer or metal sheet used, has a thickness of 0.1-10 mm, preferably 0.5-5 mm. As mentioned, it has a rectangular shape with a length of at least 10-12 m and a width of at least 3-5 m, which ultimately depends on the size of the preformed building element to be constructed on or supported thereon, and correspondingly on the size of the intermediate flexible mold element in the case where the building material is arranged on the mold element. Preferably, the support plate is, of course, larger in some extent, such that it extends beyond the size of the preformed building element or the corresponding plate-shaped mold element in both the longitudinal and transverse directions, for example, having at least 30 cm or even more.

[0052] The central feature of the support plate 1 of the present invention is that the support plate is flexible about the longitudinal axis, but reinforced about the transverse axis to resist bending. For example... Figure 1 As shown, this allows the carrier plate to change its two-dimensional flat form into a convex or tray-like form, corresponding to the convex form of the preformed building element to be constructed. This shape also corresponds to the shape of the tray-like receiving section of the mold, where the preformed building material is arranged, either directly on the carrier plate as mentioned, or on a flexible and transferable plate-like mold element.

[0053] As mentioned, flexibility about the longitudinal axis allows for a certain degree of bending. However, any bending and therefore flexibility about the transverse axis is undesirable because shape or form change cannot occur in this direction when the preformed building material is laid out and when the support plate moves through the manufacturing process. To achieve this, the support plate 1 is reinforced to resist bending about the transverse axis. This is achieved through mechanical or corresponding geometric reinforcement devices together with additional reinforcing elements arranged at the support plate. See, for example, [example missing]. Figure 2 These reinforcing devices are implemented in the form of multiple tension sections 2, which protrude from the bottom side 3 of the bearing plate 1, such as... Figure 1 and Figure 2 As shown, the building material or corresponding flexible plate-shaped mold elements are arranged on the upper receiving side 4 of the support plate 1. Each tension segment 2 has as shown... Figure 2 The U-shaped cross-section is clearly shown in the image, which has a horseshoe shape that widens towards its lower end.

[0054] Because these tension sections extend in the longitudinal direction, as will be explained later, they behave like spring elements and allow for stretching in the transverse direction. Furthermore, because they are geometrically protruding from the plate surface, the tension sections in the form of horseshoe bends 5 also act as reinforcement devices, thus preventing bending around the transverse axis or direction. They have a dual function: stretching and reinforcement. To further reinforce the load-bearing plate against this undesirable bending, rod-shaped reinforcing elements 6 are arranged in each horseshoe bend 5, such as… Figure 2 As shown in the diagram. These reinforcing elements 6 or reinforcing rods enhance stiffness. Due to the horseshoe-shaped bend of the tension section 2, the reinforcing elements 6 can be easily integrated.

[0055] Finally, since the tension section 2 or the corresponding horseshoe-shaped bend 5 is open to the receiving surface 4 of the support plate 1, an elastic sealing device 7 is provided in each horseshoe-shaped bend 5. This elastic sealing device 7 at least partially fills the horseshoe-shaped bend 5 and is flush with the receiving surface 4, thereby sealing the entire receiving surface 4. This prevents any construction material from entering one of the tension section 2 or the corresponding horseshoe-shaped bend 5.

[0056] As mentioned, the reinforcement of the bearing plate 1 is already achieved to an acceptable degree by means of the tension section 2 or the corresponding protruding horseshoe-shaped bend 5 alone. Therefore, the integration of the rod-shaped reinforcing element 6 is optional, but also preferred.

[0057] As mentioned, the tension section 5 is configured to allow the bearing plate 1 to be stretched in the lateral direction to a certain extent. Figure 3 A schematic diagram showing part of the carrier plate 1 is provided. Figure 3In the upper part, the support plate 1 is shown in its unstretched basic shape, without any force applied in the transverse direction. If the support plate 1 is stretched in the transverse direction, as... Figure 3 As indicated by arrow P1, the stretching section 2 or the corresponding horseshoe-shaped bend 5 opens, as shown. Figure 3 As shown in the lower part of the diagram, the support plate 1 is shown in a stretched position. Clearly, the horseshoe-shaped bend 5 has changed its shape and become wider, and the elastic sealing device 7 is also stretched. If the tension is increased, the stretch can be further increased, as indicated by arrow P2. Therefore, the width of the support plate 1 can be changed by this stretching, and the overall shape and profile can also be altered.

[0058] As mentioned, the stretching section 2 or the corresponding horseshoe-shaped bend acts as a spring. When they are stretched and opened, they generate a retraction force. If the tension decreases, this retraction force causes the bearing plate to retract back to its original unstretched shape, and the previously opened horseshoe-shaped bend 5 closes again.

[0059] Figure 4 A schematic diagram of the bearing plate 1 of the present invention, viewed in the longitudinal direction, is shown. In this schematic diagram, only the plate having multiple tension sections 2 is shown, such as... Figure 4 As clearly shown, these tension segments 2 are unevenly distributed in the transverse direction. The distance between two adjacent tension segments 2 is smaller in the longitudinal edge region 8 compared to the central region 9. This provides greater flexibility in the edge region 8 and allows for higher tensile strength, which in turn allows for... Figure 4 and Figure 5 The improved adaptability of the radius of the convexly curved support plate 1 shown.

[0060] Figure 4 The possibilities of bending and stretching are also illustrated. A longitudinal axis L is shown, around which bending is possible to change the shape of the support plate 1 from an almost two-dimensional shape to a convex or concave shape. This is indicated by the corresponding arrows P3 and P4. Furthermore, stretchability in the transverse direction is indicated by arrow P5. Bending in the transverse direction is prohibited, and stretching in the longitudinal direction is also not possible.

[0061] Figure 5 This is an enlarged cross-sectional view showing only the edge region 8 of the support plate 1. As shown in the edge region, a greater number of tension segments 2 are provided, thereby allowing a higher degree of stretchability and thus a higher degree of flexibility to adapt to its shape. The edge radius is significantly smaller than the center radius. As mentioned, in Figure 4 and Figure 5 These schematic diagrams do not show additional reinforcement elements because they are optional.

[0062] As mentioned, the support plate 1 serves as a carrier and conveying device, carrying and conveying the building materials throughout the manufacturing process. These building materials are either applied directly to the support plate 1 or arranged via flexible plate-shaped mold elements. Therefore, for example, the support plate 1 needs to be arranged and secured in a conveying device such as a rack, or if it is separately loaded into a heating device such as an oven, it needs to be arranged and secured to a corresponding receiving element of the heating device, etc. To achieve this, the support plate 1 is provided with fixing elements 10 in the form of hook-shaped curved plate edges 11, such as... Figure 6 As shown in the diagram. These hook-shaped fixing elements 10 extend along the entire length of each longitudinal edge of the support plate 1 and engage at corresponding receiving or hooking elements 12, which are provided, for example, at a conveying device 13 such as a frame. Figure 7 As shown in the diagram, the hook device 12 is provided with, for example, a plurality of roller elements 14 that carry the support plate 1 and allow easy longitudinal pushing of the support plate 1 for loading and unloading the support plate 1. Additionally, a guide groove 15 may be provided, in which guide pins 16 arranged at the edge 11 of the hook-shaped curved plate engage.

[0063] Figure 7 A mold structure 17 is shown, which has a mold 18 with a mold carrier 19 on which a receiving section 20, here in the form of a tray-like plate, is arranged. It should be noted that the mold 18 is, of course, much longer than shown. The mold carrier may have a length of approximately 15 m and a width of, for example, 6 m, as may the receiving section.

[0064] The receiving section 20 has a tray-shaped recess 21 with a receiving surface 22 on which a flexible plate 23 is arranged. The flexible plate 23 is made of polymer or metal and has a thickness of, for example, 0.1-10 mm. Due to the flexibility of the mold element 23, which has a rectangular shape, the mold element 23 can be perfectly adapted to the geometry of the recess 21 or the corresponding receiving surface 22. Therefore, it transforms its two-dimensional form into a convex form defined by the recess 21.

[0065] Preformed building material 24 is applied to the plate-shaped mold element 23, such as Figure 7 As shown by the dashed lines, the preformed building material includes fiber mats, such as glass fiber or carbon fiber mats, arranged longitudinally or transversely or tangentially, and overlapping or covering each other to construct a corresponding stack. Additionally, but optionally, one or more core elements made of, for example, balsa wood or foam polymers may be arranged. Finally, an adhesive, preferably a powder or granules, is applied, which can then be melted to embed the fiber mats and core elements, but only locally, so that the mat structure remains open. The adhesive is only used to secure the mat and core arrangement.

[0066] After the construction material is applied, a vacuum foil 25 is arranged, which covers the construction material 24 and extends onto the plate-shaped mold element 23. By means of a vacuum pump (not shown), the space between the vacuum foil 25 and the mold element 23 is evacuated, so that the vacuum foil 25 is drawn against the construction material 24 and the mold element 23, thereby fixing and stabilizing the construction material 24. At the same time, the vacuum also fixes the convex shape of the arrangement structure including the mold element 23, the construction material 24 and the vacuum foil 25.

[0067] After the tube vacuum is fixed, the coupling with the vacuum pump is disconnected while maintaining the vacuum. The plate-shaped mold element 23 is then transferred to the conveying device 13, where, in this embodiment, two support plates 1 are already arranged, for example, by means of... Figure 6 The fixing device is shown. It should be noted that the corresponding support plate 1 is preferably movable in the vertical direction in the frame 14 so as to bring the support plate 1 into the corresponding transfer level, where the mold element 1 can be pushed on it.

[0068] To allow this pushing movement, an air cushion can be created at the mold 18, for example, by means of a blower. This air cushion is created below the mold element 23, causing the mold element 23 to suspend on the air cushion and thus be easily pushed onto the corresponding support plate 1. The support plate 1 itself may be provided with a sliding coating, such as a specific sliding polymer, which allows the mold element 23 to be easily slidably transferred onto the support plate 1.

[0069] After being loaded onto the conveyor 13, as a further production step, the conveyor 13 may be moved, for example, to a heating device for heating the preformed building material, or, if heating is not required immediately, to a storage area.

[0070] Figure 8 An embodiment of mold structure 17 is shown, which also includes a mold 18 having a mold carrier 19 and a receiving section 20 in the form of a tray-like plate. In this embodiment, the carrier plate 1 is placed directly on the receiving section and its shape is adapted to the shape of the receiving surface 21, as shown. Since the carrier plate 1 is part of the mold structure 17, a plate-shaped mold element 23 can be arranged on the carrier plate 1, on which the building material 24 and vacuum foil 25 can be applied, or the building material 24 and vacuum foil 25 can be applied directly to the receiving surface 4 of the carrier plate 1. In any way, after the pre-formed building material is applied, the carrier plate 1 is transferred from the mold 18 to the conveyor 13, where the carrier plate 1 is fixed to the corresponding hook element 12, etc., regardless of what fixing elements are arranged at the conveyor 13.

[0071] The receiving section 22 is provided with a plurality of grooves 26 disposed in the receiving surface 21, the number of which corresponds to the number of stretching sections 2 and the number of hook-shaped curved plate edges 11. Figure 8 As shown, the stretching section 2 and the bending plate edge 11 engage in corresponding grooves, such that the bearing plate 1 contacts the receiving surface 22 with its bottom surface 3 completely flat, and complete shape adaptation is possible.

[0072] Figure 9 The image shows the engagement of the stretching section 2 or the corresponding horseshoe-shaped bend 5 in the corresponding groove 26.

[0073] Figure 10 Another embodiment of the mold structure is shown, a portion of which is the support plate 1 of the present invention. The mold structure 17 includes a mold 18 having a mold carrier 19 equipped with a receiving section 20, here in the form of a grid 27, which includes a plurality of rods 28 extending along the longitudinal mold direction. The rods 28 are connected to a plurality of cables 29 extending in the transverse direction and carrying the rods 28.

[0074] Cable 29 is secured at one end to the mold carrier, while the other end extends through the mold carrier 19 to the outside. Cable end 30 can be manually pulled out of the mold carrier 19, allowing the radius of the receiving section or corresponding grid 27 to be adapted or altered. When cable 29 is pulled out of the mold carrier 19, the grid is lifted in a certain way, becoming flatter and increasing in radius. If cable 29 is pushed back in, the grid 27 hangs in the mold carrier 19 with a smaller radius. Due to the arrangement of a number of separate cables 29, the form of the grid 27 can be locally altered, and thus the radius can be changed. This alteration may be uniform along the length of the grid, but it may also vary from one end to the other, causing the radius to become smaller or larger from one end to the other.

[0075] Since the support plate 1 is arranged on the grid 27, the radius of the support plate 1 and therefore the radius of the receiving surface 4 can also be changed accordingly.

[0076] To secure the support plate 1, the grid 27 is provided with multiple fixing elements 31, which here take the form of movable, pivotable clamps 32, such as... Figure 11 As shown in the diagram. These clamps 32 can be opened (in the open state). Figure 11 The section (shown by the dotted line) changes to a closed state, as indicated by arrow P6, thereby clamping the corresponding stretching section 2 or the corresponding horseshoe-shaped curved section 5, as shown in the example. Figure 11 As shown in the diagram. This secures the support plate 1 tightly to the grid 27, so that the support plate 1 will immediately follow any changes in the grid geometry.

[0077] The movement of clamps 32 can be controlled simultaneously, for example by a pneumatic system, so that they can be closed and opened at the same time.

[0078] In this embodiment, with Figure 8Similar to other embodiments, the build material 24 is either applied directly to the receiving surface 4 of the carrier plate 1 along with the vacuum foil 25, or the flexible plate-shaped mold element 23 is arranged on the receiving surface 4 of the carrier plate 1 following the tray-like shape of the carrier plate 1, after which the build material 24 and the vacuum foil 25 are applied to the mold element 23. After the vacuum fixation of the build material, wherever it is applied, the fixation of the carrier plate 1 is released, allowing the carrier plate 1 to be moved onto the conveyor 13, where it is fixed using appropriate fixing devices, as previously discussed.

[0079] at last, Figure 12 and Figure 13 An embodiment of how to use the carrier plate 1 of the present invention to manufacture a preform is shown.

[0080] Figure 12 A mold 18 with a receiving section 20 is shown, on which a flexible, plate-shaped mold carrier 23, shaped to fit its form, is arranged. On the receiving surface, building materials 24, here in the form of layered fiber pads 33, are arranged overlapping and stacked on top of each other. They are layered longitudinally, but may also be arranged chordally or both longitudinally and chordally. As already explained, in addition to these fiber pads 33, optional core elements and a forced adhesive are applied. After this application, a vacuum foil 25 is arranged, subsequently a vacuum is applied, and the shape of this arrangement is fixed or frozen accordingly. The mold elements 23, together with the adhesive arrangement, are then ready to be transferred to a conveying device.

[0081] The entire manufacturing structure 34 Figure 13 As shown in the diagram. Multiple molds 18a, 18b, and 18c are arranged side-by-side. On mold 18a, as per... Figure 12 As explained, mold element 23 has been provided with building materials 24, etc., and as Figure 13 As shown, it is transferred to conveyor 13 or corresponding frame 14. Frame 14 is guided on track 35, allowing it to move along molds 18a, 18b, and 18c. It is equipped with multiple support plates 1, each adapted to receive a covered mold element 23. Mold element 23a of mold 18a has just been transferred, as indicated by arrow P7. The support plates 1 are arranged in corresponding levels so that mold element 23a can be easily pushed onto, for example, a support plate 1 covered with a sliding layer, while mold 18 is also provided with sliding devices, such as air cushions or rollers.

[0082] After the mold element 23 is received in the frame 14, the frame moves to the mold 18b, as indicated by arrow P8. The mold 18b includes the mold element 23b, which is also covered with the building material 24 and is ready to be transferred to the frame 14, which is also accomplished by a simple push-movement.

[0083] After the mold elements, still needing to be arranged on mold 18c, are loaded with building material and transferred to rack 14, which is located at the entrance of heating device 36, such as an oven, heated by hot air, the support plate 1 from rack 14 is transferred into the oven, where a corresponding receiving device, such as a retaining rail or hook structure, is set up, and the support plate 1 rests on the receiving device. The transfer of the support plate 1 from rack 14 to heating device 36 is indicated by arrow P9. When heating device 36 is fully loaded, it is turned off and the heating process begins. Heating device 36 is preheated so that it always maintains heat and can perform heating quickly. During heating, the adhesive melts and embeds building material, such as a pad, into the adhesive matrix. After a defined holding time, the heated mold support 1 is transferred to cooling device 37, such as a cooling chamber, which is preferably also air-cooled. There, the inserted support plate 1, preferably simply pushed from heating device 36 into cooling device 37, is cooled to ambient air temperature. This transfer is indicated by arrow P10.

[0084] After cooling is complete, the support plates 1 are removed from the cooling unit 37, as indicated by arrow P11. They are arranged on another rack (not shown) and either moved to the manufacturing side for producing blades or blade parts, or to the storage area.

[0085] Although the invention has been described in detail with reference to preferred embodiments, the invention is not limited to the disclosed examples, and other variations can be derived by those skilled in the art from the disclosed examples without departing from the scope of the invention.

Claims

1. A support plate for producing a preform manufacturing structure for preformed components for wind turbine blades, adapted to receive a mold element (23) having preformed building material (24) on a receiving surface (4), or directly on the receiving surface (4), wherein the support plate (1) has a rectangular shape having a longer longitudinal axis and a shorter transverse axis, wherein, The bearing plate (1) is flexible about the longitudinal axis, but reinforced about the transverse axis to resist bending, and is stretchable along the transverse axis, but rigid along the longitudinal axis; The bearing plate (1) is formed with one or more stretching segments (2), the stretching segments (2) having a U-shaped profile open to the receiving surface (4) and extending along the longitudinal axis.

2. The bearing plate according to claim 1, characterized in that, The support plate is made of polymer or metal.

3. The bearing plate according to claim 2, characterized in that, The polymer is polypropylene.

4. The bearing plate according to claim 2, characterized in that, The metal is aluminum.

5. The bearing plate according to claim 2, characterized in that, The support plate is made of metal with a polymer coating on at least one side receiving the preformed building material (24) or the mold element (23).

6. The bearing plate according to claim 1 or 2, characterized in that, The support plate has a thickness of 0.1-10 mm.

7. The bearing plate according to claim 1 or 2, characterized in that, The support plate has a thickness of 0.5-5 mm.

8. The bearing plate according to claim 1, characterized in that, The stretching section (2) has a horseshoe-shaped cross section.

9. The bearing plate according to claim 1 or 8, characterized in that, Multiple stretching segments (2) are provided, which are equidistant when viewed along the transverse axis, or are arranged at a smaller distance in at least one segment compared to at least one other segment.

10. The bearing plate according to claim 1 or 2, characterized in that, An elastic sealing device (7) is provided, which at least partially fills the stretching segment (2) or each stretching segment (2) and is flush with the receiving surface (4), or the receiving surface (4) is provided by an elastic sheet covering the stretching segment (2).

11. The bearing plate according to claim 1 or 2, characterized in that, One or more rod-shaped reinforcing elements (6) are arranged in the tension section (2) or at least some of each tension section (2).

12. The bearing plate according to claim 1 or 2, characterized in that, A first fixing element (10) is disposed on the side of the plate extending along the longitudinal axis, the first fixing element (10) being adapted to fix the bearing plate (1) to the plate bearing device.

13. The bearing plate according to claim 12, characterized in that, The first fixing element (10) is implemented in the form of a hook-shaped bent plate edge (11).

14. A mold structure for producing preformed components for wind turbine blades, comprising a mold carrier (19) having a receiving section (20) adapted to receive a carrier plate (1) according to any one of the preceding claims. in, The receiving section (20) is constructed of a receiving plate having a receiving container (21) having a tray-like form adapted to receive the support plate (1), the support plate (1) being adapted to the tray-like form by bending about its longitudinal axis, and wherein the receiving container (21) is provided with one or more slots (26), each slot (26) being adapted to receive a U-shaped stretched section (2) of the support plate (1); or The receiving section (20) is constructed of a grid (27), which includes a plurality of rods (28) extending along the longitudinal direction of the mold carrier (19), and wherein the grid (27) is provided with one or more second fixing elements (31) for fixing the support plate (1), and wherein the second fixing element (31) or each second fixing element (31) is a clamp (32) adapted to clamp the U-shaped stretching section (2) of the support plate (1).

15. The mold structure according to claim 14, characterized in that, The cross-sectional shape of the grid (27) can be changed so as to change the cross-sectional shape of the support plate (1) placed on the grid (27).

16. The mold structure according to claim 15, characterized in that, The rod (28) is connected to a plurality of cables (29) extending in the lateral direction of the mold carrier (19), such that the degree of bending of the cross section of the grid (27) can be changed by pulling or releasing the cables (29).

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