Wind power blade and core material structure

Abstract

The invention discloses a wind power blade and a core material structure, and the wind power blade comprises a skin layer which comprises an upper skin layer and a lower skin layer; the core material layer is arranged between the upper skin layer and the lower skin layer, the core material layer comprises a plurality of main body areas with different thicknesses and at least one transition area with the gradually-changed thickness, and the adjacent main body areas are in transition connection through the transition area; a plurality of first grooves and a plurality of second grooves are formed in the two side faces, perpendicular to the thickness direction of the core material layer, of the core material layer and face the opposite side faces, and the extending direction of at least part of the first grooves intersects with the extending direction of at least part of the second grooves; the reinforcing layer is arranged on at least one side of the core material layer, and the reinforcing layer covers the transition area of each core material structure. According to the wind power blade and the core material structure, both the fixing stability of the core material and the overall cost of the wind power blade can be considered.

Description

Technical Field

[0001] This application belongs to the field of wind power generation technology, and in particular relates to a wind turbine blade and core material structure. Background Technology

[0002] With the development of the wind power industry, the manufacturing of wind turbine blades is facing the demand for high material performance and low overall cost. As the main part of the wind turbine blade shell, the material and processing technology of the core material have a significant impact on the overall performance and cost of the wind turbine blade.

[0003] In the shell structure of wind turbine blades, multiple core materials are usually spliced ​​together to form an integral layered structure, and skins are set on the upper and lower surfaces respectively. Finally, resin is injected to fix the core materials and skins to form a complete shell structure.

[0004] Currently, due to the need for core material blocks of different thicknesses at different locations in the shell, the inconsistent thickness between the core material blocks leads to the formation of a stepped structure. This stepped structure causes defects such as fiber wrinkles or resin-rich areas in the bonding area between the core material and the skin after bonding, affecting the overall bonding stability between the core material layer structure and the skin.

[0005] To improve bonding stability, intersecting deep grooves and through-holes are typically created on the upper surface of the core material block to increase the wetting area of ​​both the upper and lower surfaces, ensuring good adhesion between the two surfaces and the upper and lower skins. However, this method leads to core material blocks falling off during installation, requiring the entire lower surface to be covered with hot-melt fabric to fix the core structure, resulting in increased resin consumption and thus increased overall cost. Therefore, balancing the stable fixation of the core structure within the shell with the overall cost of the blade shell has become a pressing issue. Summary of the Invention

[0006] This application provides a wind turbine blade and core material structure that can balance the stability of the core material and the overall cost of the wind turbine blade.

[0007] This application provides a wind turbine blade, comprising: a skin layer including an upper skin layer and a lower skin layer; a core material layer disposed between the upper skin layer and the lower skin layer, the core material layer including multiple main areas of different thicknesses and at least one transition area with a gradually changing thickness, adjacent main areas being connected by the transition area, and multiple first grooves and multiple second grooves opening toward opposite sides on two sides of the core material layer perpendicular to its thickness direction, at least some of the first grooves extending in directions intersecting with at least some of the second grooves extending in directions; and a reinforcing layer disposed on at least one side of the core material layer, the reinforcing layer covering at least one transition area of ​​the core material layer.

[0008] The wind turbine blades shown above have a reinforcing layer that also covers at least a portion of the main body area connected to the transition zone.

[0009] The wind turbine blade shown above has multiple main sections of varying thickness arranged sequentially along a second direction, which is the axial direction of the wind turbine blade.

[0010] As shown in the wind turbine blade above, the transition zone is located on both sides of the main body in the second direction, and each transition zone extends along the first direction. The reinforcing layer has a straight structure with the same extension direction as the transition zone. The first direction is the chord direction of the wind turbine blade.

[0011] As shown in the wind turbine blades above, the transition zone is set around each main area, and the reinforcement layer has the same annular shape as the transition zone.

[0012] On the other hand, this application also provides a core material structure, wherein multiple core material structures are connected to form the core material layer of the wind turbine blade for forming the above-mentioned wind turbine blade, at least some of the core material structures have a main body area and a transition area, and two adjacent core material structures with different thicknesses are connected by a transition area of ​​one of the core material structures.

[0013] In the above core material structure, each core material structure has multiple first grooves and multiple second grooves. The multiple first grooves include at least one first sub-groove extending along a first direction, and the multiple second grooves include at least one second sub-groove extending along a second direction. The opening depth of each first sub-groove and each second sub-groove facing the opposite side is greater than the bottom thickness to the opposite side. The first direction and the second direction are intersecting.

[0014] In the core material structure described above, the first sub-groove and the second sub-groove intersect and form a connecting hole at the intersection, and the connecting hole is provided through both sides of the core material layer.

[0015] In the core material structure described above, at least one third sub-groove is included among the plurality of first grooves. The opening depth of the third sub-groove facing the opposite side is less than the opening depth of the first sub-groove facing the opposite side. Each third sub-groove extends along the second direction, and each third sub-groove is staggered from the second sub-groove in the first direction.

[0016] In the core material structure described above, at least one fourth sub-groove is included among the plurality of second grooves. The opening depth of the fourth sub-groove toward the opposite side is less than the opening depth of the second sub-groove toward the opposite side. Each fourth sub-groove extends along a first direction, and each fourth sub-groove is staggered from the first sub-groove in a second direction.

[0017] The wind turbine blade of this application embodiment includes a skin layer, a core material layer, and a reinforcing layer. The core material layer and the reinforcing layer are both disposed between the upper skin layer and the lower skin layer of the skin layer. The core material layer includes multiple main areas with different thicknesses and at least one transition area with gradually changing thickness. Each adjacent main area is connected by the transition area with gradually changing thickness, forming a smooth surface of the core material layer as a whole, so that the surface of the core material layer can adhere to the upper skin layer and the lower skin layer, achieving a stable bonding effect.

[0018] To further enhance the bonding effect, the core material layer has a first groove and a second groove on each of its two sides, increasing the bonding area between the two side surfaces and the upper and lower skin layers. At least a portion of the first groove's extension direction and at least a portion of the second groove's extension direction intersect, providing bonding forces in different directions on both sides and ensuring a stable bonding effect for the core material layer. Because the first and second grooves are located on both sides, the groove density they form is relatively low, reducing the likelihood of flaking. A reinforcing layer is only placed in the transition zone where the thickness gradually changes, achieving overall protection and reinforcement of the core material layer. This eliminates the need for the reinforcing layer to be placed on the entire side of the core material layer, resulting in a smaller overall area and reduced installation costs, thereby lowering the overall cost of the wind turbine blade.

[0019] Therefore, the wind turbine blade and core material structure of the present application embodiment can take into account both the fixation stability of the core material layer and the overall cost of the wind turbine blade. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments of this application will be briefly introduced below. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the overall structure of the wind turbine blade according to an embodiment of this application;

[0022] Figure 2 This is a schematic diagram of the core material layer of a wind turbine blade according to an embodiment of this application;

[0023] Figure 3 This is a schematic diagram of the connecting holes in the core material structure of a wind turbine blade according to an embodiment of this application;

[0024] Figure 4 This is a schematic diagram of one of the core material structures of a wind turbine blade according to an embodiment of this application;

[0025] Figure 5 This is a schematic diagram showing the arrangement of the first and second grooves in the core material structure according to an embodiment of this application.

[0026] Figure 6This is a schematic diagram illustrating the fit between the core material layer and the reinforcing layer of a wind turbine blade according to an embodiment of this application.

[0027] Figure 7 This is a schematic diagram of the fit between the core material layer and the reinforcing layer of a wind turbine blade according to another embodiment of this application.

[0028] Explanation of icon numbers:

[0029] 1. Skin layer; 11. Upper skin layer; 12. Lower skin layer;

[0030] 2. Core material layer; 2a. Main body area; 2b. Transition area; 21. First trench; 211. First sub-trench; 212. Third sub-trench; 2121. Main body area trench; 2122. Transition area trench; 22. Second trench; 221. Second sub-trench; 222. Fourth sub-trench; 23. Connecting hole;

[0031] 3. Reinforcing layer; 4. Core material structure;

[0032] X, the first direction; Y, the second direction. Detailed Implementation

[0033] The features and exemplary embodiments of various aspects of this application will be described in detail below. To make the objectives, technical solutions, and advantages of this application clearer, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only intended to explain this application and not to limit it. For those skilled in the art, this application can be implemented without some of these specific details. The following description of the embodiments is merely to provide a better understanding of this application by illustrating examples.

[0034] like Figures 1 to 7 As shown, this application embodiment provides a wind turbine blade, comprising: a skin layer 1, including an upper skin layer 11 and a lower skin layer 12; a core material layer 2, disposed between the upper skin layer 11 and the lower skin layer 12, the core material layer 2 including multiple main body regions 2a of different thicknesses and at least one transition region 2b of gradually varying thickness, adjacent main body regions 2a being connected by the transition region 2b, and multiple first grooves 21 and multiple second grooves 22 respectively opened towards opposite sides on two sides of the core material layer 2 perpendicular to its thickness direction, at least some of the first grooves 21 extending in the direction of extension of at least some of the second grooves 22 intersecting the direction of extension of extension of the first grooves 21; and a reinforcing layer 3, disposed on at least one side of the core material layer 2, the reinforcing layer 3 covering at least one transition region 2b of the core material layer 2.

[0035] In specific implementation, the wind turbine blade of this application embodiment includes a skin layer 1, a core material layer 2, and a reinforcing layer 3. The core material layer 2 and the reinforcing layer 3 are both disposed between the upper skin layer 11 and the lower skin layer 12 of the skin layer 1. The core material layer 2 includes multiple main body regions 2a of different thicknesses and at least one transition region 2b with a gradually changing thickness. Adjacent main body regions 2a are connected by the transition region 2b, forming a smooth surface of the core material layer 2 as a whole. This allows the surface of the core material layer 2 to adhere to the upper skin layer 11 and the lower skin layer 12, achieving a stable bonding effect. To further improve the bonding effect, the two sides of the core material layer 2 respectively have a first groove 21 and a second groove 22 to increase the bonding area between the two side surfaces and the upper skin layer 11 and the lower skin layer 12. At least a portion of the extension direction of the first groove 21 and at least a portion of the extension direction of the second groove 22 intersect, providing bonding forces in different directions on both sides, ensuring a stable bonding effect for the core material layer 2. Since the first groove 21 and the second groove 22 are located on both sides and extend in different directions, the groove density formed by each is relatively low, making it less prone to chipping. By only setting the reinforcing layer 3 in the transition zone 2b where the thickness gradually changes, the core material layer 2 can be protected and reinforced as a whole. This eliminates the need for the reinforcing layer 3 to be located on the entire side of the core material layer 2, and also makes it possible to set grooves on both sides of the core material layer 2. The overall area of ​​the reinforcing layer 3 is small, reducing the layout cost of the reinforcing layer 3, thereby reducing the overall cost of the wind turbine blade.

[0036] Therefore, the wind turbine blade and core material structure of this application embodiment can take into account both the fixation stability of the core material layer 2 and the overall cost of the wind turbine blade.

[0037] Furthermore, a transition zone 2b with gradually varying thickness is used to connect the main body zones 2a with different thicknesses, forming a smooth transition connection between adjacent main body zones 2a. There will be no stress caused by the step structure at the connection point, so there will be no stress concentration phenomenon in the entire core material layer 2, thus ensuring the structural stability of the core material layer 2.

[0038] In this embodiment, the coverage area of ​​the reinforcing layer 3 on one side of the core material layer 2 ranges from 1% to 20%, with a minimum coverage area of ​​1%. The reinforcing layer 3 can completely cover the transition area 2b of the core material layer to achieve sufficient protection, thereby giving the core material layer 2 sufficient structural stability and reducing the probability of chipping. Furthermore, the overall area of ​​the reinforcing layer 3 will not exceed 20%, which reduces the layout cost of the reinforcing layer 3 while ensuring overall structural stability, thus reducing the overall cost of the wind turbine blade.

[0039] like Figure 6 and Figure 7As shown in the embodiment of the present application, the wind turbine blade has a reinforcing layer 3 that also covers at least a portion of the main body region 2a connected to the transition region 2b.

[0040] In specific implementation, when the reinforcing layer 3 covers the transition area 2b, its edge portion also covers at least a portion of the main body area 2a connected to the transition area 2b. Since the reinforcing layer 3 has an integral layer structure, the transition area 2b and the main body area 2a can be further connected through the reinforcing layer 3, which improves the connection strength between the transition area 2b and the main body area 2a, making the core material layer 2 less prone to chipping, thereby further enhancing the protection and reinforcement of the core material layer 2.

[0041] In this embodiment, the coverage area of ​​the reinforcing layer 3 over the main body region 2a ranges from 1% to 10%, with a minimum coverage area of ​​1%. This ensures that the reinforcing layer 3 connected to the main body region 2a has sufficient area to provide adequate support at the connection between the main body region 2a and the transition region 2b, thereby ensuring the connection strength between the transition region 2b and the main body region 2a and making the core material layer 2 less prone to chipping. Furthermore, the coverage area of ​​the reinforcing layer 3 relative to the main body region 2a will not exceed 10%. Under the premise of ensuring a stable connection between the transition region 2b and the main body region 2a, the arrangement cost of the reinforcing layer 3 can be further reduced, thereby reducing the overall cost of the wind turbine blade.

[0042] like Figure 2 , Figure 6 and Figure 7 As shown in the embodiment of this application, the wind turbine blade has multiple main body regions 2a of different thicknesses arranged sequentially along the second direction Y; wherein the first direction X is the chord direction of the wind turbine blade, and the second direction Y is the axial direction of the wind turbine blade.

[0043] In specific implementation, in the second direction Y, the axial length of the wind turbine blade is relatively long and the thickness gradually changes. It needs to be formed by multiple main body regions 2a with different thicknesses and transition regions 2b between the main body regions 2a to meet the overall structural requirements of the wind turbine blade. In the first direction X, the chordal length of the wind turbine blade is relatively short. The thickness of the same main body region 2a in the chordal direction remains unchanged, which can meet the structural requirements of the wind turbine blade in the chordal direction. In the first direction X, it is not necessary to splice multiple main body regions 2a with different thicknesses, which reduces the overall production difficulty of the wind turbine blade.

[0044] like Figure 6 As shown in the embodiment of the wind turbine blade of this application, the transition zone 2b is disposed on both sides of the main body region 2a in the second direction Y, and each transition zone 2b extends along the first direction X. The reinforcing layer 3 has a straight line structure with the same extension direction as the transition zone 2b. Figure 6 This embodiment is a schematic diagram showing the fit between the core layer 2 and the reinforcing layer 3. Figure 6The shaded area represents reinforcement layer 3.

[0045] In practice, multiple main body regions 2a are arranged sequentially along the second direction Y, and each main body region 2a has a transition region 2b on both sides of the second direction Y. Therefore, the transition region 2b enables a transitional connection between adjacent main body regions 2a. By adopting this method of setting the transition region 2b, the transition connection of the transition region 2b is only performed at the connection between adjacent main body regions 2a, reducing the setting area of ​​the transition region 2b, thereby reducing the overall processing difficulty of the core material layer 2.

[0046] Furthermore, the reinforcing layer 3 has a straight structure that extends in the same direction as the transition zone 2b, so that the reinforcing layer 3 can completely cover the transition zone 2b, thereby ensuring the protective and reinforcing effect on the core material layer 2 and reducing the probability of chipping. In addition, the straight structure of the reinforcing layer 3 does not completely cover the entire surface of the core material layer 2, which reduces the arrangement cost of the reinforcing layer 3.

[0047] like Figure 7 As shown, in another embodiment of the wind turbine blade of this application, a transition zone 2b is disposed around each main body zone 2a, and the reinforcing layer 3 has the same annular shape as the transition zone 2b. Figure 7 This embodiment is a schematic diagram showing the fit between the core layer 2 and the reinforcing layer 3. Figure 7 The shaded area represents reinforcement layer 3.

[0048] In practice, each main body area 2a is surrounded by a transition area 2b. When adjacent main body areas 2a are connected, they can be connected through the transition area 2b with a gradual change in thickness, thus achieving a smooth transition between main body areas 2a. The edge parts of each main body area 2a that are not connected to other main body areas 2a also achieve a gradual change in thickness through the transition area 2b, thereby reducing the step height of the core material layer 2 at the edge, making the connection between the core material layer 2 and the skin layer 1 more stable, and reducing the difficulty of the connection process.

[0049] The reinforcing layer 3 has the same annular shape as the transition zone 2b, so that the reinforcing layer 3 can completely cover the transition zone 2b, thus ensuring the protective and reinforcing effect on the core material layer 2 and reducing the probability of falling off. In addition, the annular shape of the reinforcing layer 3 does not completely cover the entire surface of the core material layer 2, which reduces the arrangement cost of the reinforcing layer 3.

[0050] This application embodiment also provides a core material structure, wherein, for forming the above-mentioned wind turbine blade, multiple core material structures 4 are connected to form the core material layer 2 of the wind turbine blade, at least some of the core material structures 4 have a main body region 2a and a transition region 2b, and two adjacent core material structures 4 with different thicknesses are connected by the transition region 2b of one of the core material structures 4.

[0051] In practical implementation, when connecting multiple core material structures 4, if the thicknesses of two adjacent core material structures 4 are different, a transition zone 2b is used for transitional connection. If the thicknesses of two adjacent core material structures 4 are the same, they can be directly connected without the need for a transition zone 2b. The provision of a transition zone 2b in some core material structures 4 ensures that when connecting core material structures 4 of different thicknesses, the transition zone 2b can provide a smooth transition surface, avoiding stepped structures with large height differences. This would cause obvious wrinkles or deformations in the skin layer 1 that is in contact with the surface of the core material layer 2, leading to a decrease in the performance of the skin layer 1. Therefore, the transition zone 2b in some core material structures 4 ensures a stable bonding effect between the core material layer 2 and the skin layer 1, as well as the performance of the skin layer 1.

[0052] In some optional embodiments, at least a portion of the core material structure 4 further includes a reinforcing layer 3. The reinforcing layer 3 is disposed on at least one side of its corresponding core material structure 4 and covers the transition region 2b and at least a portion of the main body region 2a. The reinforcing layer 3 provides protection for the entire transition region 2b of the core material structure 4, as well as the connection between the main body region 2a and the transition region 2b, thereby increasing the overall strength of the transition region 2b and making the connection between the main body region 2a and the transition region 2b more stable. This enhances the overall strength of the core material structure 4 and, consequently, improves the structural stability of the core material layer 2 formed by connecting multiple core material structures 4.

[0053] like Figures 2 to 5 As shown in the embodiment of this application, the core material structure 4 has a plurality of first grooves 21 and a plurality of second grooves 22. The plurality of first grooves 21 include at least one first sub-groove 211 extending along the first direction X, and the plurality of second grooves 22 include at least one second sub-groove 221 extending along the second direction Y. The opening depth of each first sub-groove 211 and each second sub-groove 221 facing the opposite side is greater than the bottom thickness of each sub-groove to the opposite side. The first direction X and the second direction Y are intersecting.

[0054] In specific implementation, the opening depth of each first sub-groove 211 and each second sub-groove 221 facing the opposite side is greater than the thickness of the bottom to the opposite side, ensuring that each first sub-groove 211 and each second sub-groove 221 has sufficient opening depth. When the adhesive such as resin is contained in the first sub-groove 211 and the second sub-groove 221, there can be sufficient contact area between it and the groove wall. Therefore, after bonding and molding, sufficient adhesion can be ensured between the upper skin layer 11 and the first sub-groove 211 and between the lower skin layer 12 and the second sub-groove 221, thereby further improving the stable bonding effect between the core material layer 2 and the skin layer 1.

[0055] Specifically, the angle between the first direction X and the second direction Y is 30° to 90°, that is, the angle between the extension direction of the first sub-groove 211 and the extension direction of the second sub-groove 221 is 30° to 90°. Within this angle range, the angle range of the adhesive force provided by the first sub-groove 211 in its extension direction and the adhesive force provided by the second sub-groove 221 in its extension direction is 30° to 90°. This ensures that the horizontal and vertical components of the adhesive force at the intersection of the two angles can meet the adhesive force requirements between the core material layer 2 and the skin layer 1, thereby ensuring the stable bonding between the core material layer 2 and the skin layer 1.

[0056] Preferably, the extension direction of the first sub-groove 211 is perpendicular to the extension direction of the second sub-groove 221, which can ensure that the adhesion between the core material layer 2 and the skin layer 1 can be stably bonded when the blade shell is subjected to chordal force and axial force. Therefore, this orientation setting is more suitable for the stress situation of the blade shell during use and meets the adhesion stability requirements between the core material layer 2 and the skin layer 1 during the rotation of the wind turbine blade.

[0057] In the core material structure of this application embodiment, the bottom of each first sub-groove 211 to its opposite side and the bottom of each second sub-groove 221 to its opposite side both have a bottom thickness D, where 1.0mm≤D≤5.0mm.

[0058] It should be noted that in the core material layer 2, the bottom of each first groove 21 and the bottom of each second groove 22 to their respective opposite sides are part of the structure of the core material layer 2, and this part is the bottom structure of the core material layer 2.

[0059] In specific implementation, the thickness D of the bottom of each first sub-groove 211 to its opposite side and the bottom of each second sub-groove 221 to its opposite side is set to be between 1.0mm and 5.0mm. The minimum thickness D is 1.0mm, which avoids the core material layer 2 from breaking at the bottom due to excessive thickness. During the overall transfer of the core material layer 2 or the connection with the skin layer 1, it avoids the occurrence of partial core material layer 2 falling off and ensures the overall integrity of the core material layer 2. The maximum thickness D is 5.0mm, which ensures that each first sub-groove 211 and each second sub-groove 221 has sufficient groove depth to ensure the connection area between the two sides of the core material layer 2 and the skin layer 1, thereby ensuring the connection stability between the core material layer 2 and the skin layer 1.

[0060] like Figure 3 As shown in the embodiment of this application, the core material structure has a first sub-groove 211 and a second sub-groove 221 intersecting and forming a connecting hole 23 at the intersection. The connecting hole 23 extends through both sides of the core material layer 2.

[0061] In specific implementation, a connecting hole 23 is formed at the intersection of the first sub-groove 211 and the second sub-groove 221. The connecting hole 23 can be sequentially set through the first sub-groove 211 and the second sub-groove 221, thereby forming a hole-like structure that runs through both sides of the core material layer 2. By using the connecting hole 23 formed by the intersection of the first sub-groove 211 and the second sub-groove 221, it is not necessary to separately open holes during the manufacturing process of the core material layer 2, which greatly improves the manufacturing efficiency of the core material layer 2.

[0062] When bonding the core layer 2 and the skin layer 1 with adhesive, adhesive can be filled into the first sub-groove 211 on one side of the core layer 2. After flowing, the adhesive reaches the connecting hole 23 and flows from the connecting hole 23 to the second sub-groove 221 on the other side of the core layer 2. Therefore, by setting the connecting hole 23, the adhesive filling operation can be completed on only one side of the core layer 2, which improves the bonding efficiency between the core layer 2 and the skin layer 1, ensures the effective connection between the core layer 2 and the skin layer 1, reduces the risk of connection failure between the core layer 2 and the skin layer 1, and thus ensures the overall structural performance of the wind turbine blade.

[0063] Furthermore, by providing the connecting holes 23, it is unnecessary to break the core material layer 2 into pieces during its processing, layup, or bonding to ensure that the adhesive penetrates all the grooves of the core material layer 2. Breaking into pieces refers to fracturing the bottom portion corresponding to some grooves, thereby connecting the upper and lower surfaces of the core material layer 2. Therefore, the connecting holes 23 reduce the need for breaking into pieces and improve the processing efficiency of the core material layer 2.

[0064] In the core material structure of this application embodiment, the connecting hole 23 has a cross-sectional area S, 1 mm², at any position in the thickness direction. 2 ≤S≤4mm 2 .

[0065] In specific implementation, the cross-sectional area S of the connecting hole 23 ranges from 1 mm2 to 4 mm2. Therefore, the minimum cross-sectional area S of the connecting hole 23 is 1 mm2, which ensures that the connecting hole 23 has sufficient area for the adhesive to pass through, avoiding the situation where the adhesive cannot completely pass through the connecting hole 23 and thus cannot reach the groove on the other side for bonding. Therefore, the minimum value of the cross-sectional area S of the connecting hole 23 ensures the bonding strength and bonding effect on both sides of the core material layer 2. The maximum cross-sectional area S of the connecting hole 23 is 4 mm2, which avoids the situation where the cross-sectional area S of the connecting hole 23 is too large, resulting in excessive resin consumption. Excessive resin consumption will lead to an increase in the overall weight of the wind turbine blade. Therefore, the setting of the maximum cross-sectional area of ​​the connecting hole 23 ensures the overall lightweight design of the wind turbine blade.

[0066] Specifically, since the connecting hole 23 is formed by the connection of the first sub-groove 211 and the second sub-groove 221, the cross-sectional area S of the hole is related to the width of the first sub-groove 211 and the second sub-groove 221. The width of the first sub-groove 211 and the second sub-groove 221 is both in the range of 1 mm to 2 mm. Within this width range, the first sub-groove 211 and the second sub-groove 221 can provide sufficient bonding area for the adhesive to ensure the connection strength between the core layer 2 and the skin layer 1, and avoid the situation where the bottom layer is prone to breakage due to excessively large groove width.

[0067] like Figure 2 and Figure 5 As shown in the embodiment of this application, the core material structure includes at least one third sub-groove 212 among the plurality of first grooves 21. The opening depth of the third sub-groove 212 toward the opposite side is less than the opening depth of the first sub-groove 211 toward the opposite side. Each third sub-groove 212 extends along the second direction Y, and each third sub-groove 212 is staggered from the second sub-groove 221 in the first direction X.

[0068] In specific implementation, the third sub-groove 212 extends along the second direction Y, and its extension direction intersects with the first sub-groove 211. When the adhesive is injected into the first groove 21 of the core material layer 2, both the intersecting first sub-groove 211 and the third sub-groove 212 contain adhesive, thereby increasing the bonding area between the core material layer 2 and the upper skin layer 11 and improving the bonding effect between the two.

[0069] The depth of the third sub-groove 212 facing the opposite side is less than the depth of the first sub-groove 211 facing the opposite side. This design avoids the situation where the thickness of the base corresponding to both the third sub-groove 212 and the first sub-groove 211 is too small, which would cause the core material layer 2 to form multiple blocky structures that are prone to breakage. Therefore, the depth of the third sub-groove 212 is set to improve the adhesion of the core material layer 2 while also ensuring the structural stability of the core material layer 2, further enhancing the structural stability of the formed wind turbine blade.

[0070] Furthermore, the third sub-groove 212 is staggered with the second sub-groove 221 in the first direction X, which avoids the third sub-groove 212 and the second sub-groove 221 from being connected in the thickness direction, thus preventing the core material layer 2 from forming an integral layer structure and ensuring the structural stability of the core material layer 2.

[0071] like Figure 4 and Figure 5As shown in the embodiment of this application, the core material structure includes at least one fourth sub-groove 222 among the plurality of second grooves 22. The opening depth of the fourth sub-groove 222 toward the opposite side is less than the opening depth of the second sub-groove 221 toward the opposite side. Each fourth sub-groove 222 extends along the first direction X, and each fourth sub-groove 222 is staggered from the first sub-groove 211 in the second direction Y.

[0072] In specific implementation, the fourth sub-groove 222 extends along the first direction X, and its extension direction intersects with the second sub-groove 221. When the adhesive is injected into the second groove 22 of the core material layer 2, both the intersecting second sub-groove 221 and the fourth sub-groove 222 contain adhesive, thereby increasing the bonding area between the core material layer 2 and the lower skin layer 12 and improving the bonding effect between the two.

[0073] The depth of the fourth sub-groove 222 facing the opposite side is less than the depth of the second sub-groove 221 facing the opposite side. This design avoids the situation where the thickness of the base corresponding to both the fourth sub-groove 222 and the second sub-groove 221 is too small, which would cause the core material layer 2 to form multiple blocky structures that are prone to breakage. Therefore, the depth of the fourth sub-groove 222 is set to improve the adhesion of the core material layer 2 while also ensuring the structural stability of the core material layer 2, further enhancing the structural stability of the formed wind turbine blade.

[0074] Furthermore, the fourth sub-groove 222 is staggered with the first sub-groove 211 in the first direction X, which avoids the fourth sub-groove 222 and the first sub-groove 211 from being connected in the thickness direction, thus preventing the core material layer 2 from forming an integral layer structure and ensuring the structural stability of the core material layer 2.

[0075] Therefore, by setting a third sub-groove 212 and a fourth sub-groove 222 on both sides of the core material layer 2, the injection efficiency of the adhesive on both sides of the core material layer 2 is improved, and the laying process of the core material layer 2 is simplified.

[0076] Specifically, the opening depth of each third sub-groove 212 and each fourth sub-groove 222 facing the opposite side is less than the thickness of the bottom to the opposite side. This ensures that the bottom corresponding to the third sub-groove 212 and the fourth sub-groove 222 has sufficient thickness to ensure the structural stability of the core material layer 2 and reduce the probability of block falling off.

[0077] like Figure 2 and Figure 4As shown in the embodiment of this application, the core material structure includes a third sub-groove 212 comprising at least one main region groove 2121 disposed in the main region 2a and at least one transition region groove 2122 disposed in the transition region 2b, wherein the at least one main region groove 2121 and the at least one transition region groove 2122 are alternately arranged in the first direction X.

[0078] In practice, at least one main area groove 2121 and at least one transition area groove 2122 are alternately arranged in the first direction X, thereby providing adhesive force for the core material layer 2 at different positions in the first direction X, further improving the connection stability between the core material layer 2 and the skin layer 1.

[0079] Specifically, the end of the main area groove 2121 extends into the transition area 2b. The end portion of the main area groove 2121 alternates with the transition area groove 2122 in the transition area 2b, thereby forming a groove arrangement area with a high density in part of the transition area 2b. This groove arrangement area is located at the intersection of the main area 2a and the transition area 2b, thus providing a large bonding area for the intersection area of ​​the core material layer 2 and ensuring the connection stability between each area of ​​the core material layer 2 and the skin layer 1.

[0080] In some alternative embodiments, the fourth sub-groove 222 may be configured in the same way as the third sub-groove 212, that is, it includes a fourth sub-groove 222 located in the main body region 2a and a fourth sub-groove 222 located in the transition region 2b, which can provide adhesive force between the core material layer 2 and the lower skin layer 12 at different positions in the first direction X, so as to further improve the connection stability between the core material layer 2 and the skin layer 1.

[0081] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising..." does not exclude the presence of additional identical elements in the process, method, article, or apparatus that includes said element.

[0082] The above description is merely a specific implementation of this application. Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, modules, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here. It should be understood that the protection scope of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the protection scope of this application.

Claims

1. A wind turbine blade, characterized in that, include: The skin layer (1) includes an upper skin layer (11) and a lower skin layer (12); A core material layer (2) is disposed between the upper skin layer (11) and the lower skin layer (12). The core material layer (2) includes multiple main body regions (2a) with different thicknesses and at least one transition region (2b) with gradually changing thickness. Adjacent main body regions (2a) are connected by the transition region (2b). The core material layer (2) has multiple first grooves (21) and multiple second grooves (22) on its two sides perpendicular to its thickness direction, respectively, which are opened towards the opposite side. The extension direction of at least a portion of the first grooves (21) intersects the extension direction of at least a portion of the second grooves (22). A reinforcing layer (3) is disposed on at least one side of the core material layer (2), and the reinforcing layer (3) covers at least one transition region (2b) of the core material layer (2).

2. The wind turbine blade according to claim 1, characterized in that, The reinforcing layer (3) also covers at least a portion of the main body region (2a) connected to the transition region (2b).

3. The wind turbine blade according to claim 1 or 2, characterized in that, The multiple main body regions (2a) of different thicknesses are arranged sequentially along the second direction (Y); Wherein, the second direction (Y) is the axial direction of the wind turbine blade.

4. The wind turbine blade according to claim 3, characterized in that, The transition zone (2b) is located on both sides of the main body area (2a) in the second direction (Y), and each transition zone (2b) extends along the first direction (X). The reinforcing layer (3) has a straight structure with the same extension direction as the transition zone (2b). Wherein, the first direction (X) is the chord direction of the wind turbine blade.

5. The wind turbine blade according to claim 3, characterized in that, The transition zone (2b) is disposed around each of the main body zones (2a), and the reinforcing layer (3) has the same annular shape as the transition zone (2b).

6. A core material structure, characterized in that, For forming a wind turbine blade as described in any one of claims 1 to 5, a plurality of the core material structures (4) are connected to form the core material layer (2) of the wind turbine blade, at least a portion of the core material structures (4) have the main body region (2a) and the transition region (2b), and two adjacent core material structures (4) of different thicknesses are connected by the transition region (2b) of one of the core material structures (4).

7. The core material structure according to claim 6, characterized in that, Each of the core material structures (4) has a plurality of first grooves (21) and a plurality of second grooves (22). The plurality of first grooves (21) include at least one first sub-groove (211) extending along a first direction (X). The plurality of second grooves (22) include at least one second sub-groove (221) extending along a second direction (Y). The opening depth of each first sub-groove (211) and each second sub-groove (221) facing the opposite side is greater than the bottom thickness to the opposite side. The first direction (X) and the second direction (Y) are intersecting.

8. The core material structure according to claim 7, characterized in that, The first sub-groove (211) intersects with the second sub-groove (221) and forms a connecting hole (23) at the intersection. The connecting hole (23) is provided through both sides of the core material layer (2).

9. The core material structure according to claim 7, characterized in that, The plurality of first grooves (21) also include at least one third sub-groove (212), the opening depth of the third sub-groove (212) facing the opposite side is less than the opening depth of the first sub-groove (211) facing the opposite side, each of the third sub-grooves (212) extends along the second direction (Y), and each of the third sub-grooves (212) is staggered from the second sub-groove (221) in the first direction (X).

10. The core material structure according to claim 9, characterized in that, The plurality of second grooves (22) also include at least one fourth sub-groove (222), the fourth sub-groove (222) having a depth toward the opposite side less than the depth of the second sub-groove (221) toward the opposite side, each of the fourth sub-grooves (222) extending along the first direction (X), and each of the fourth sub-grooves (222) being staggered from the first sub-groove (211) in the second direction (Y).

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