First blade segment for segmented wind turbine rotor blade

Abstract

A first blade segment (50) for a segmented wind turbine rotor blade (10), comprising: a spar cap (40) comprising at least a first spanwise region (52) and a second spanwise region (54); and a load transfer laminate (64) disposed in the second spanwise region (54) of the spar cap (40); wherein the load transfer laminate (64) comprises fibers, and wherein less than 80% of the fibers are oriented in the spanwise direction (44) of the first blade segment (50).

Description

Technical Field

[0001] The present disclosure relates generally to wind turbines, and more particularly to a first blade segment for a segmented wind turbine rotor blade, to a wind turbine rotor blade, and to a method of producing the first blade segment. Background Art

[0002] Wind power is considered to be one of the cleanest and most environmentally friendly energy sources currently available, and for this reason, wind turbines have received increasing attention. Modern wind turbines typically include a tower, a generator, a gearbox, a nacelle, and one or more rotor blades. The rotor blades obtain kinetic energy from the wind using the known airfoil principle, and the kinetic energy is transferred by rotational energy to rotate the shaft, which connects the rotor blades to the gearbox, or directly to the generator if a gearbox is not used. The generator then converts the mechanical energy into electrical energy that can be deployed to the utility grid.

[0003] The size of the rotor blades contributes to the energy efficiency of the wind turbine. Specifically, an increase in the size of the rotor blades can increase the energy output of the wind turbine. The economic benefits of the increased wind turbine size or rotor blade size must be weighed against the corresponding costs of manufacturing, transporting, assembling or repairing the wind turbine. One strategy for reducing the costs of preforming, transporting and erecting a wind turbine with increased size rotor blades is to manufacture the rotor blades in blade segments. The blade segments can be assembled and connected at joints to form a complete rotor blade. The assembly and joining of the blade segments can be performed, for example, after the individual blade segments have been transported to the erection location.

[0004] However, the joints between the blade segments need to withstand the high loads experienced by the rotor blades. Furthermore, the available space within the aerodynamic shape of the rotor blades for the joint components and structural components of the blades is limited.

[0005] Accordingly, the present disclosure is directed to a first blade segment for a segmented wind turbine rotor blade that may provide a robust, secure and / or compact connection to a second blade segment of the wind turbine rotor blade. Summary of the invention

[0006] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0007] In one aspect, the present disclosure is directed to a first blade segment for a segmented wind turbine rotor blade. The first blade segment includes a spar cap. The spar cap includes at least a first spanwise region and a second spanwise region. The first blade segment further includes a load transfer laminate disposed in the second spanwise region of the spar cap. The load transfer laminate includes fibers, wherein less than 80% of the fibers are oriented along the spanwise direction of the first blade segment. It should be understood that the first blade segment may further include any of the features as described herein.

[0008] In another aspect, the present disclosure is directed to a segmented wind turbine rotor blade comprising a first blade segment according to embodiments described herein.

[0009] In yet another aspect, the present disclosure is directed to a method for producing a first blade segment for a segmented wind turbine rotor blade. The method includes arranging a component assembly in a blade segment mold. Arranging the component assembly includes arranging a spar cap in the blade segment mold, the spar cap including at least a first spanwise region and a second spanwise region. Arranging the component assembly includes arranging a load transfer laminate material in the second spanwise region of the spar cap, wherein the load transfer laminate material is arranged such that less than 80% of the fibers of the load transfer laminate material are oriented in the spanwise direction. The method further includes, after arranging the component assembly, impregnating the component assembly with an impregnation material. It should be understood that the method may further include any of the additional operations and / or features as described herein.

[0010] These and other features, aspects and advantages of the present invention will be further supported and described with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and together with the description serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] A complete and enabling disclosure of the present invention including the best mode thereof to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which: Figure 1 A perspective view of a wind turbine is shown; Figure 2 A schematic diagram of a segmented rotor blade for a wind turbine is shown; Figure 3 A cross-sectional view of a rotor blade is shown; Figure 4A -B shows a schematic cross-sectional view of a first blade segment and a second blade segment for assembling a wind turbine rotor blade according to an exemplary embodiment; Figure 5 shows a schematic cross-sectional view of a portion of a first blade segment according to some embodiments of the present disclosure; Figure 6shows a schematic cross-sectional view of a portion of a first blade segment according to further embodiments; Figure 7 a flow chart showing a method of producing a first blade segment according to an embodiment; and Fig. 8A -E shows various operations for producing a first blade segment according to an embodiment. DETAILED DESCRIPTION

[0012] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the present invention without limiting the present invention. In fact, it will be clear to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the present invention. For example, a feature shown or described as a part of an embodiment can be used in conjunction with another embodiment to produce yet another embodiment. Therefore, it is intended that the present invention covers such modifications and variations as fall within the scope of the appended claims and their equivalents.

[0013] Figure 1 A modern upwind wind turbine 2 is shown having a tower 4, a nacelle 6 and a rotor with a substantially horizontal rotor shaft. The rotor comprises a hub 8 and at least one rotor blade 10 extending radially from the hub 8, each blade 10 having a blade root 16 closest to the hub 8 and a blade tip 14 farthest from the hub 8. For example, Figure 1 As shown in FIG, the rotor may include three rotor blades 10 .

[0014] Figure 2 A schematic diagram of a wind turbine blade 10 is shown. In a spanwise direction 44 of the blade 10, the blade 10 comprises a root region 24 closest to the hub, an airfoil region 28 farthest from the hub 8, and a transition region 26 between the root region 24 and the airfoil region 28. The blade 10 comprises a leading edge 18 facing the direction of rotation of the blade 10 when the blade 10 is mounted on the hub, and a trailing edge 20 facing in the opposite direction of the leading edge 18.

[0015] The airfoil region 28 (or profile region) has a blade shape configured to generate lift, while the root region 24 has a substantially circular or elliptical cross-section due to structural considerations, which, for example, makes it easier and safer to mount the blade 10 to the hub 8. The diameter (or chord) of the root region 24 can be substantially constant along the entire root region 24. The transition region 26 has a transition profile that gradually changes from the circular or elliptical shape of the root region 24 to the airfoil profile of the airfoil region 28. The chord length of the transition region 26 typically increases with increasing distance from the hub 8. The airfoil region 28 has an airfoil profile having a chord extending between the leading edge 18 and the trailing edge 20 of the blade 10. The width of the chord decreases with increasing distance from the hub 8. The shoulder 30 of the blade 10 is defined as the position where the blade 10 has its maximum chord length. The shoulder 30 is typically provided at the boundary between the transition region 26 and the airfoil region 28.

[0016] According to an embodiment of the present disclosure, the wind turbine rotor blade 10 comprises at least two blade segments, in particular exactly two blade segments. Figure 2 A first blade segment 50 and a second blade segment 80 are shown joined at a parting line 78 of the rotor blade. In some embodiments, the rotor blade 10 may include more than two blade segments, such as exactly three blade segments or exactly four blade segments. The at least two blade segments include a first blade segment 50 and a second blade segment 80. The second blade segment 80 may be joined to the first blade segment 50 such that the second blade segment 80 extends from the first blade segment 50 toward a blade tip 14 of the rotor blade 10. The rotor blade 10 may extend from a blade root 16 of the rotor blade 10 to a blade tip 14 of the rotor blade 10 along a blade axis in a spanwise direction 44. Some embodiments of the present disclosure may be directed to a rotor blade 10 including a first blade segment 50 and a second blade segment 80. Embodiments may be directed to a set of at least two blade segments for assembling a rotor blade 10, the set including a first blade segment 50 and a second blade segment 80 according to embodiments described herein.

[0017] In an embodiment, the first blade segment 50 is a root segment of the rotor blade 10. Specifically, the first blade segment 50 may include a blade root 16 of the rotor blade 10. In an embodiment, the first blade segment 50 is connected or configured to be connected to the rotor hub 8. For example, the blade root 16 may be configured to be connected to a pitch bearing of the rotor hub 8. In other embodiments, the first blade segment may be joined to a root-side blade segment in a direction toward the root and to a second blade segment in a direction toward the blade tip.

[0018] In some embodiments, the second blade segment 80 is a tip segment including the blade tip 14. For example, Figure 2The second blade segment 80 is shown as a tip segment joined to the first blade segment 50, which is a root segment configured to be joined to the rotor hub 8. In other embodiments, the second blade segment 80 may be an intermediate blade segment extending between the first blade segment and additional blade segments, which may be connected to the second blade segment at opposite ends of the first blade segment.

[0019] During operation of the wind turbine 2, the rotor blade 10 is subjected to high loads. Specifically, the outer segments (such as the second blade segment 80) may be affected by the high speed and strong force of the wind acting on the blade segments. The forces acting on the second blade segment 80 and the reaction forces from the first blade segment 50 may be transmitted between the first blade segment 50 and the second blade segment 80 at the joint between the blade segments. The joint area of ​​the blade segments around the joint may be designed to provide stability to withstand the transmission of such loads between the blade segments. However, the design of the joint area may further involve considerations about the limited available space within the aerodynamic shape of the rotor blade 10, the size and weight of the joint components of the joint, and / or considerations about the complexity of the joint or the complexity of the assembly procedure for assembling the blade segments into a complete rotor blade 10. Thus, the present disclosure is directed to a first blade segment that can provide or support a robust, safe and / or compact connection with a second blade segment.

[0020] According to an embodiment of the present disclosure, the first blade segment 50 includes a spar cap 40. Specifically, the first blade segment 50 may include two spar caps 40. The spar caps 40 may extend along a spanwise direction 44 of the first blade segment 50. The spar caps 40 may be arranged on opposite sides of the first blade segment 50. One of the spar caps 40 may be arranged along a pressure side of the first blade segment 50. Another of the spar caps 40 may be arranged along a suction side of the first blade segment 50. In an embodiment, the spar caps 40 may be connected to one or more shear webs 42 of the first blade segment 50. The shear webs 42 may extend along a spanwise direction 44 and extend between the spar caps 40 in a flapping direction 48.

[0021] For example, Figure 3A cross section of a first blade segment 50 is schematically shown, for example in the airfoil region 28 of the blade 10 and in particular in a first spanwise region 52 of the spar cap 40 according to embodiments described herein. The first blade segment 50 comprises a blade shell 56 formed by combining a first shell half 34 and a second shell half 36 of the first blade segment 50. Each of the first shell half 34 and the second shell half 36 provides an outer skin of the first blade segment 50 between the leading edge 18 and the trailing edge 20 of the first blade segment 50. The first blade segment 50 comprises a spar extending in a spanwise direction 44 of the first blade segment 50. The spar comprises a spar cap 40 and a shear web 42. Each of the shear webs 42 may be connected to two spar caps 40, in particular to the spar caps 40 in the flapping direction 48.

[0022] According to some embodiments, the spar cap 40 of the first blade segment 50 is formed via pultrusion. The spar cap 40 may include spar cap fibers, in particular carbon fibers and / or glass fibers. In some embodiments, more than 80% of the spar cap fibers, in particular more than 85% or more than 90% of the spar cap fibers may be oriented along the span direction 44. For example, about 95% of the spar cap fibers may be oriented along the span direction 44. The spar cap 40 may be particularly configured to support loads in the span direction 44.

[0023] According to an embodiment, the first blade segment 50 includes a blade shell 56. Specifically, the first blade segment 50 may include an inner shell 57 and an outer shell 58. The outer shell 58 may face the outer side of the first blade segment 50. The inner shell 57 may face the inner side of the first blade segment 50. In an embodiment, the spar cap 40 of the first blade segment 50 is arranged between the inner shell 57 and the outer shell 58. For example, Figure 3 Each of the spar caps 40 is shown disposed between an inner shell 57 and an outer shell 58 of a blade shell 56 .

[0024] In an embodiment, the first blade segment 50 includes a load transfer laminate 64. In an embodiment, the load transfer laminate 64 is disposed between the spar cap 40 and at least one of the inner shell 57 and the outer shell 58. For example, the load transfer laminate 64 may be disposed between the spar cap 40 and the inner shell 57 of the first blade segment 50. In other embodiments, the load transfer laminate 64 is disposed between the spar cap 40 and the outer shell 58. In some embodiments, the load transfer laminate 64 may be disposed between the spar cap 40 and the outer shell 58 and between the spar cap 40 and the inner shell 57. Specifically, a portion of the load transfer laminate 64 may be disposed between the spar cap 40 and the outer shell 58, and another portion of the load transfer laminate 64 may be disposed between the spar cap 40 and the inner shell 57. In some embodiments, the load transfer laminate 64 may be disposed in contact with the spar cap 40.

[0025] According to an embodiment, the spar cap 40 includes at least a first span-wise region 52 and a second span-wise region 54. The first span-wise region 52 and the second span-wise region 54 may be different span-wise regions. Specifically, the first span-wise region 52 and the second span-wise region 54 may be adjacent span-wise regions or non-intersecting span-wise regions. Specifically, the second span-wise region 54 may be smaller than the first span-wise region 52. In an embodiment, the load transfer laminate 64 is arranged in the second span-wise region 54. In some embodiments, the load transfer laminate 64 may not extend from the second span-wise region 54 into the first span-wise region 52. The load transfer laminate 64 may be completely arranged in the second span-wise region 54 of the spar cap 40.

[0026] According to some embodiments, the second spanwise region 54 of the spar cap 40 includes a tip-side end portion of the spar cap 40. The first spanwise region 52 may be arranged towards the blade root 16 relative to the second spanwise region 54. In an embodiment, the second spanwise region 54 may include less than 25% of the spanwise length of the spar cap 40, in particular less than 20% or less than 15%.

[0027] In an embodiment, the first blade segment 50 comprises a receiver 66 for receiving the connection member 82 of the second blade segment 80 of the segmented wind turbine rotor blade 10. The receiver 66 may be arranged at a tip-side end of the spar cap 40 or at a tip-side end of the first blade segment 50. In some embodiments, the receiver 66 may be arranged at least partially in the second span-wise region 54 of the spar cap 40. In other embodiments, the receiver 66 may be arranged completely within the second span-wise region 54. For example, the second span-wise region may include the span-wise region of the receiver 66 and further include a length of up to 50% of the span-wise receiver length towards the blade root 16, in particular up to 30% of the receiver length or up to 20% of the receiver length.

[0028] In an embodiment, the receiver 66 may be configured to receive a connection member 82 in a receiving space 72 of the receiver 66. The receiving space 72 may extend along the spanwise direction 44 toward the blade root 16 up to a receiver partition 74 of the receiver 66. The connection member 82 of the second blade segment 80 may be configured, for example, as a beam. The connection member 82 may extend further toward the blade root 16 of the rotor blade 10 than the second blade shell 81 of the second blade segment 80. The connection member 82 of the second blade segment 80 may include one or more structural components of the second blade segment 80, such as a spar or one or more spar caps of the second blade segment 80. In some embodiments, the receiver 66 and the connection member 82 are configured to be connected via an interlocking device (e.g., via a pin joint). For example, each of the receiver 66 and the connection member 82 may include at least one pin hole for inserting a pin 70. The pin 70 may be inserted into the at least one pin hole and at least partially pass through the receiver 66 and the connection member 82.

[0029] For example, Figure 4A and 4B A first blade segment 50 and a second blade segment 80 of a wind turbine rotor blade 10 are schematically shown. Figure 4A In FIG. 1 , the first blade segment 50 and the second blade segment 80 are shown in a separated state. Figure 4B The first blade segment 50 comprises a spar cap 40, which extends along the span direction 44 of the first blade segment 50 to the tip-side end of the first blade segment 50. The receiving piece 66 is arranged at the tip-side end of the spar cap 40, in particular in the second span direction region 54 of the spar cap 40. Figure 4A and 4B In the exemplary embodiment of FIG. 5 , the load transfer laminate 64 is disposed between the spar cap 40 and the receiver 66 , and more particularly between the spar cap 40 and the inner shell (not shown) of the first blade segment 50 . Figure 4A As shown in FIG. 1 , the receiving member 66 includes a receiving space 72 for receiving a connecting member 82 of a second blade segment 80. Figure 4B 84, the connecting member 82 is inserted into the receiver 66 along the spanwise direction 44, for example, up to the receiver spacer 74 of the receiver 66. The pin 70 is inserted through the receiver pin hole 68 and the connecting member pin hole 84 to mechanically interlock the first blade segment 50 and the second blade segment 80. In an embodiment, the load transfer laminate 64 is specifically configured to transfer loads between the receiver 66, the spar cap 40 and / or the blade shell 56 of the first blade segment 50. For example, the load transfer laminate 64 can transfer loads and forces acting on the second blade segment 80 and transmitted to the receiver 66 via the connecting member 82.

[0030] According to an embodiment, the load transfer laminate 64 includes fibers, wherein less than 80% of the fibers, particularly less than 75% of the fibers, or more particularly less than 70% of the fibers are oriented along the span direction 44 of the first blade segment 50. In some embodiments, more than 50% of the fibers, particularly more than 60% of the fibers, are oriented along the span direction 44 of the first blade segment 50. For example, between 50% and 80% of the fibers may be oriented along the span direction 44. In particular, the load transfer laminate 64 may be configured to transfer spanwise loads and torsional loads between the receiver 66, the spar cap 40, and / or the blade shell 56.

[0031] The orientation of the fibers along the spanwise direction 44 of the first blade segment 50 may be at least substantially parallel to the longitudinal blade axis or span of the first blade segment 50, for example, deviating from the parallel orientation by up to 10 degrees or up to 5 degrees. It should be understood that the longitudinal blade axis or span may follow the curvature of the first blade segment 50 or the curvature of the rotor blade 10.

[0032] According to some embodiments, the chord-wise width of the load transfer laminate 64 in the chord-wise direction 46 is greater than the chord-wise receiver width of the receiver 66. For example, the chord-wise width of the load transfer laminate 64 in the chord-wise direction 46 of the first blade segment 50 may be at least 1.1 times greater, in particular at least 1.2 times greater, than the chord-wise receiver width.

[0033] According to some embodiments, the load transfer laminate 64 may extend further in the spanwise direction 44 toward the blade root 16 than the receiver 66. Figure 4A , the spanwise length of the load transfer laminate 64 is greater than the spanwise receiver length of the receiver 66. In other embodiments, the spanwise length of the load transfer laminate 64 is less than the spanwise receiver length of the receiver 66. In some embodiments, the chordwise width of the load transfer laminate 64 is greater than the chordwise spar cap width of the spar cap 40. The load transfer laminate may provide, in particular, load distribution between the receiver 66, the spar cap 40, and / or the blade shell 56.

[0034] According to some embodiments, the spar cap 40 has a first spar cap flapwise thickness in the first spanwise region 52 and a second spar cap flapwise thickness in the second spanwise region 54, wherein the first spar cap flapwise thickness is greater than the second spar cap flapwise thickness. Specifically, the first spar cap flapwise thickness may be a maximum spar cap flapwise thickness of the spar cap 40. The second spar cap flapwise thickness may be a minimum spar cap flapwise thickness of the spar cap 40. For example, the spar cap 40 may have two or more spar cap layers, in particular layers formed via pultrusion. The number of spar cap layers may decrease from the root side of the spar cap 40 to the tip side of the spar cap 40 along the spanwise direction 44. In an embodiment, the spar cap 40 may have a maximum number of spar cap layers in the first spanwise region 52 and a reduced number of spar cap layers in the second spanwise region 54. The reduced number of spar cap layers may provide more space for the receiver 66, in particular in the flapwise direction 48.

[0035] In an embodiment, the fibers of the load transfer laminate 64, the fibers of the inner shell 57, and / or the fibers of the outer shell 58 are provided by a fiber material. Specifically, the inner shell 57, the outer shell 58, and the load transfer laminate 64 can be formed by impregnating the fiber material, in particular, in the blade segment mold 92. The fiber material can be impregnated with an impregnation material such as a resin. The blade segment mold 92 can be configured to form at least a portion of the first blade segment 50, such as a first half or a second half of the first blade segment 50.

[0036] In some embodiments, the fiber material may include a sheet of fiber fabric. Specifically, the fiber fabric may be a unidirectional fiber fabric or a biaxial fiber fabric. In a unidirectional fiber fabric, at least 90%, in particular at least 95% or more particularly 100% of the fibers are oriented substantially in the same direction. In a biaxial fiber fabric, a portion of the fibers are oriented along a first axis, and a second portion of the fibers are oriented along a second axis different from the first axis. For example, half of the fibers in a biaxial fiber fabric may be arranged perpendicular to the other half of the fibers. A plurality of fiber fabric sheets may be arranged in a blade segment mold to form an inner shell 57, an outer shell 58 and / or a load transfer laminate 64. Subsequently, the fiber fabric sheet may be impregnated with an impregnation material.

[0037] In an embodiment, each of the inner shell 57, the outer shell 58 and / or the load transfer laminate 64 includes one or more fabric layers. Each fabric layer may include an impregnated fiber fabric sheet. Specifically, the fabric layer may be a unidirectional fabric layer including an impregnated unidirectional fiber fabric sheet. The fabric layer may be a biaxial fabric layer including an impregnated biaxial fiber fabric sheet.

[0038] According to some embodiments, the load transfer laminate 64 comprises a plurality of fabric layers. The fabric layers comprise fibers of the load transfer laminate 64. In embodiments, the load transfer laminate 64 comprises one or more biaxial fabric layers, in particular a plurality of biaxial fabric layers. The one or more biaxial fabric layers may be provided such that the fibers extend at approximately plus or minus 45 degrees relative to the span direction 44. In some embodiments, the load transfer laminate 64 comprises one or more unidirectional fabric layers. The one or more unidirectional fabric layers may be provided such that the fibers extend along the span direction 44.

[0039] According to an embodiment, the fabric layer comprises at least one first layer having fibers oriented in one or more first directions, and at least one second layer having fibers oriented in one or more second directions different from the one or more first directions. In particular, the load transfer laminate 64 may comprise a plurality of biaxial fabric layers and at least one unidirectional fabric layer. In some embodiments, the number of biaxial fabric layers is at least 2 times, in particular at least 4 times, the number of unidirectional fiber fabric layers. In an embodiment, the fabric layers of the load transfer laminate 64 may comprise one or more glass fiber fabric layers and / or one or more carbon fiber fabric layers. Arranging the fibers in the span direction and arranging the fibers obliquely to the span direction may provide support, in particular, with respect to span loads and torsional loads.

[0040] In an embodiment, the load transfer laminate 64 has a flap thickness. The flap thickness may be non-uniform in the span direction 44. Specifically, the number of fabric layers of the load transfer laminate 64 may vary along the span direction 44. The load transfer laminate 64 may have a maximum flap thickness in the second span region 54. In some embodiments, the flap thickness of the load transfer laminate 64 tapers from the maximum flap thickness in at least one span direction 44, and particularly in both span directions 44.

[0041] According to an embodiment, the load transfer laminate 64 is at least partially co-located with the receiver 66 in the spanwise direction 44. In some embodiments, the maximum flapwise thickness may be provided at the spanwise location of the receiver baffle 74 or in the spanwise receiver baffle region. The spanwise receiver baffle region may include the spanwise location of the receiver baffle 74 and 10% of the spanwise receiver length in both spanwise directions.

[0042] Figure 5 and Figure 6 A schematic cross-sectional view of an exemplary embodiment is shown. Figure 5 and Figure 6 Each shows a tip-side end of a first blade segment 50, wherein a receiver 66 is arranged at the tip-side end, wherein only one spar cap 40, one load transfer laminate 64 and one side of the shell are shown, and the other side of the first blade segment 50 is omitted in the schematic diagram. Figure 5 The first blade segment 50 includes a spar cap 40 having a first spar cap layer 60 and a second spar cap layer 61 formed by pultrusion. The first spar cap layer 60 extends to the tip side end of the first blade segment 50 along the span direction 44. The second spar cap layer 61 extends approximately to the receiving piece 66 along the span direction 44. The spar cap 40 is arranged between the inner shell 57 and the outer shell 58. The first blade segment 50 further includes a load transfer laminate 64, Figure 5 , the load transfer laminate 64 is disposed between the spar cap 40 and the inner shell 57. The load transfer laminate 64 has a maximum flapwise thickness in the flapwise direction 48, which is co-located with the root-side end of the receiver 66. The flapwise thickness of the load transfer laminate 64 tapers from the maximum flapwise thickness in both spanwise directions 44.

[0043] exist Figure 6 In FIG. 4 , the spar cap 40 includes, for example, a first spar cap layer 60 , a second spar cap layer 61 , and a third spar cap layer 62 . The number of layers of the spar cap 40 decreases toward the tip side end portion of the spar cap 40 . Figure 6Further shown is a load transfer laminate 64 arranged between the spar cap 40 and the outer shell 58 of the first blade segment 50. The load transfer laminate 64 has a maximum flapwise thickness that is constant in the spanwise direction 44 in a region around the root-side end of the receiver 66. The flapwise thickness tapers from the maximum flapwise thickness in both spanwise directions 44.

[0044] According to some embodiments, the load transfer laminate is formed from a ply or sheet of fiber fabric. The sheet may have a length in the span direction of at most 2 times, in particular at most 1.7 times or at most 1.4 times, the length of the receiver. For example, at least one of the fiber fabric sheets of the load transfer laminate may have approximately the same length as the length of the receiver. The fiber fabric sheets of the load transfer laminate may have different lengths in the span direction.

[0045] According to an embodiment, the first blade segment 50 includes two spar caps 40 and a load transfer laminate 64 according to embodiments described herein for each of the spar caps 40. In some embodiments, the load transfer laminate 64 for the spar caps 40 may be provided with the same or similar features, for example with respect to the corresponding spar caps 40 or with respect to the receiver 66. In other embodiments, a load transfer laminate as described herein may be provided differently for each of the spar caps 40. According to still other embodiments, only one load transfer laminate 64 as described herein may be provided for one of the spar caps.

[0046] According to an embodiment of the present disclosure, a method 100 for producing a first blade segment 50 for a segmented wind turbine rotor blade 10 is provided, in particular for producing a first blade segment 50 according to the embodiments described herein. For example, Figure 7 1 shows a flow chart of the method 100. In some embodiments, the method 100 may include forming (block 110) the spar caps 40. The spar caps 40 may be formed via pultrusion. For example, the spar caps 40 may be formed in a spar cap die 90 (particularly a pultrusion die). Fig. 8A As shown in , the spar caps 40 may be formed to include more than one spar cap layer, for example, a first spar cap layer 60 and a second spar cap layer 61. According to embodiments described herein, the spar caps 40 may include at least a first span-wise region 52 and a second span-wise region 54.

[0047] In an embodiment, the method 100 includes arranging the component assembly in the blade segment mold 92. For example, Figure 8B A portion of an empty blade segment mold 92 is shown. In some embodiments, arranging the component assembly may include arranging (block 120) a shell fiber material 94 for the shell 58 in the blade segment mold 92. The shell fiber material 94 may include one or more fiber fabric sheets, particularly biaxial fiber fabric sheets. Figure 8CA biaxial fiber fabric sheet, such as for the outer shell 58 , is shown arranged in a blade segment mold 92 .

[0048] According to an embodiment, arranging the component assembly includes arranging (block 130) a load transfer laminate 96, in particular a load transfer laminate for use in a load transfer laminate 64 according to embodiments described herein. Specifically, the load transfer laminate may be a fiber material as described herein. In some embodiments, the load transfer laminate 96 may be arranged above the shell fiber material 94. In some embodiments, the load transfer laminate 96 is arranged before arranging the spar cap 40 in the blade segment mold 92. The load transfer laminate 96 may be arranged in a spanwise region of the blade segment mold 92 corresponding to the second spanwise region 54 of the spar cap 40. For example, Fig.8D A plurality of fiber fabric sheets for the load transfer laminate 64 are shown arranged in a region corresponding to the second spanwise region 54 of the spar cap 40. In other embodiments, the load transfer laminate 96 may be arranged after the spar cap 40 is arranged in the blade segment mold 92. Specifically, the load transfer laminate may be arranged on top of the spar cap 40 in the second spanwise region 54 of the spar cap 40. In still further embodiments, a portion of the load transfer laminate may be arranged on the shell fiber material 94, and another portion of the load transfer laminate may be arranged on top of the spar cap 40 after the spar cap 40 is arranged in the blade segment mold 92. In an embodiment, the load transfer laminate 96 is arranged such that less than 80% of the fibers, specifically less than 75% of the fibers, or more specifically less than 70% of the fibers of the load transfer laminate 96 are oriented in the spanwise direction 44. Specifically, the load transfer laminate 96 may be arranged such that the fibers are oriented as in the load transfer laminate 64 described herein.

[0049] According to an embodiment, arranging the component assembly includes arranging (block 140) the spar cap 40 in the blade segment mold 92 (eg, above the shell fiber material 94). Fig. 8E As shown in , the spar caps 40 may be disposed over the skin fiber material 94 and over the load transfer laminate material 96 .

[0050] In an embodiment, arranging the component assembly may further include arranging (block 150 ) inner shell fiber material for the inner shell 57 over the spar caps 40 .

[0051] According to an embodiment, the method further comprises, after arranging the component assembly in the blade segment mold 92, impregnating (block 160) the component assembly with an impregnation material. For example, impregnating the component assembly may be performed by a vacuum impregnation process. The component assembly, in particular the outer shell fiber material 94, the inner shell fiber material and / or the load transfer laminate material 96 may be impregnated with an impregnation material, in particular with a resin. The impregnated component assembly may provide an outer shell 58 formed by the outer shell fiber material 94, a load transfer laminate 64 formed by the load transfer laminate material 96, and / or an inner shell 57 formed by the inner shell fiber material. The impregnated component assembly may further combine the prefabricated spar cap 40 with the outer shell fiber material 94, the inner shell fiber material and / or the load transfer laminate material 96. The method 100 may in particular provide a first half of a first blade segment 50.

[0052] The method 100 may further include forming a second half of the first blade segment 50. The second half may be formed similarly to the first half. The second half may be formed using a different blade segment mold. In an embodiment, the method may include connecting a receiver 66 to the first half and / or the second half of the first blade segment 50. Specifically, according to embodiments described herein, the receiver 66 may be connected to the first half in the second spanwise region 54 of the spar cap 40. The method 100 may further include connecting one or more shear webs 42 to the first half and the second half. The method 100 may further include connecting the first half and the second half to form the first blade segment 50, in particular the first blade segment 50 according to embodiments described herein.

[0053] Embodiments of the present disclosure may provide the following advantages: Load transfer between blade segment components including spar caps, blade shells and / or receivers of blade joints may be improved. In particular, the transfer of spanwise loads and / or torsional loads in the joint region of a segmented rotor blade may be improved. Furthermore, loads and forces transmitted via the blade joint may be distributed by the load transfer laminate. According to embodiments, more space may be provided for the receiver within the aerodynamic shape of the rotor blade. Embodiments may particularly improve the robustness, stability and / or safety of a wind turbine rotor blade.

[0054] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The scope is defined by the appended claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

1. A first blade segment (50) for a segmented wind turbine rotor blade (10), comprising - a spar cap (40) comprising at least a first spanwise region (52) and a second spanwise region (54); and - a load transfer laminate (64) arranged in a second spanwise region (54) of the spar cap (40); wherein the load transfer laminate (64) comprises fibers, and wherein less than 80% of the fibers are oriented along the spanwise direction (44) of the first blade segment (50).

2. The first blade segment (50) according to claim 1, wherein the first blade segment (50) includes a receiver (66) for receiving a connecting member (82) of a second blade segment (80) of the segmented wind turbine rotor blade (10); and wherein the receiver (66) is at least partially arranged in the second spanwise region (54) of the spar cap (40).

3. The first blade segment (50) of claim 2, wherein a chord-wise width of the load transfer laminate (64) is greater than a chord-wise receiver width of the receiver (66).

4. The first blade segment (50) according to any one of the preceding claims, wherein the load transfer laminate (64) has a flapwise thickness that is non-uniform in the spanwise direction (44).

5. The first blade segment (50) of claim 4, wherein the load transfer laminate (64) has a maximum flapwise thickness in the second spanwise region (54), and wherein the flapwise thickness tapers from the maximum flapwise thickness in at least one spanwise direction (44).

6. A first blade segment (50) according to any one of the preceding claims, wherein the load transfer laminate (64) comprises a fabric layer, the fabric layer comprising fibers of the load transfer laminate (64), and wherein the fabric layer comprises at least one first layer having fibers oriented along one or more first directions, and wherein the fabric layer comprises at least one second layer having fibers oriented along one or more second directions different from the one or more first directions.

7. The first blade segment (50) of claim 6, wherein the fabric layers of the load transfer laminate (64) include a plurality of biaxial fabric layers and at least one unidirectional fabric layer.

8. The first blade segment (50) according to any one of the preceding claims, wherein the load transfer laminate (64) comprises one or more glass fiber fabric layers and / or one or more carbon fiber fabric layers.

9. The first blade segment (50) according to any one of the preceding claims, wherein the second span-wise region (54) of the spar cap (40) comprises a tip-side end portion of the spar cap (40).

10. The first blade segment (50) of any one of the preceding claims, wherein the spar cap (40) has a first spar cap flapwise thickness in the first spanwise region (52) and a second spar cap flapwise thickness in the second spanwise region (54), and wherein the first spar cap flapwise thickness is greater than the second spar cap flapwise thickness.

11. The first blade segment (50) according to any one of the preceding claims, wherein the spar cap (40) is formed via pultrusion.

12. The first blade segment (50) according to any one of the preceding claims, further comprising an inner shell (57) and an outer shell (58), the load transfer laminate (64) being arranged between the spar cap (40) and at least one of the inner shell (57) and the outer shell (58); wherein the inner shell (57), the outer shell (58) and the load transfer laminate (64) are formed by impregnating fiber material in a blade segment mold (92).

13. A segmented wind turbine rotor blade (10) comprising a first blade segment (50) according to any one of the preceding claims.

14. A method (100) of producing a first blade segment (50) for a segmented wind turbine rotor blade (10), comprising: - arranging the component assembly in a blade segment mould (92), wherein arranging the component assembly comprises: - arranging a spar cap (40) in the blade segment mould (92), the spar cap (40) comprising at least a first spanwise region (52) and a second spanwise region (54); - arranging a load transfer laminate (96) in a second spanwise region (54) of the spar cap (40), wherein the load transfer laminate (96) is arranged such that less than 80% of the fibers of the load transfer laminate (96) are oriented in the spanwise direction (44); and - After arranging the component assembly, impregnating the component assembly with an impregnation material.

15. The method (100) of claim 14, further comprising: - before arranging the spar caps (40), forming the spar caps (40) via pultrusion.

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