Wind turbine blade forming assembly, forming mould assembly and forming method

Abstract

This application relates to the field of wind turbine blades, and discloses a wind turbine blade forming assembly, a forming mold assembly, and a forming method. The wind turbine blade forming assembly includes a blade root layer structure, a blade root flange structure, a forming mold, and a sealing element. The blade root flange structure includes a flange body and pre-embedded bolts installed on the flange body. The forming mold includes a main body and a protrusion. The protrusion protrudes from a functional surface of the main body along the axial direction, and a portion of the flange body faces the functional surface along the axial direction. Along the stacking direction, the sealing element is disposed on a support surface of the protrusion near the cavity, and the peripheral side of the flange body abuts against the side of the sealing element facing away from the protrusion. This improves the sealing effect between the blade root flange structure and the forming mold.

Description

Technical Field

[0001] This application belongs to the field of wind turbine blades, and particularly relates to a wind turbine blade forming component, forming mold component, and forming method. Background Technology

[0002] Wind turbine blades are one of the core components of wind turbines. They are blade-shaped structures installed on the hub of a wind turbine that capture wind energy and convert it into mechanical energy, thereby driving the generator rotor to rotate and generate electricity.

[0003] Currently, the mainstream production method for wind turbine blades is mold forming, in which reinforcing materials such as glass fiber and blade root embedded parts are vacuum-injected and cured within a mold. Among these processes, the matching of the blade root embedded parts with the blade root flange structure, and the sealing between the blade root flange structure and the mold, are particularly critical, affecting the forming effect of the wind turbine blade. Improving the sealing performance between the blade root flange structure and the mold is one of the urgent problems that needs to be solved. Summary of the Invention

[0004] This application provides a wind turbine blade forming assembly, a forming mold assembly, and a forming method, which can improve the sealing effect between the blade root flange structure and the forming mold.

[0005] On one hand, embodiments of this application provide a wind turbine blade forming assembly, including a blade root layer structure, a blade root flange structure, a forming mold, and a seal. The blade root flange structure includes a flange body and pre-embedded bolts installed on the flange body. Along the axial direction of the wind turbine blade, the pre-embedded bolts are located on one side of the flange body. Along the stacking direction, the pre-embedded bolts are located inside the blade root layer structure. The flange body is located at one end of the blade root layer structure along the axial direction. The forming mold includes a main body and a protrusion. The main body is bent and enclosed along the circumferential direction of the wind turbine blade to form a cavity. The protrusion protrudes from the functional surface of the main body along the axial direction. The blade root layer structure is laid in the cavity. The blade root flange structure is installed in the forming mold. Along the axial direction, a portion of the flange body is opposite to the functional surface. Along the stacking direction, the seal is located on the support surface of the protrusion near the cavity. The seal extends along its own length from one end of the main body along the circumferential direction to the other end. The peripheral side of the flange body abuts against the side of the seal facing away from the protrusion.

[0006] In some embodiments of this application, the main body includes a blade root segment, which is used to form a blade root preform.

[0007] In some embodiments of this application, the main body includes a blade root section, an intermediate section and a blade tip section arranged sequentially along the axial direction, which are used to form the shell of the wind turbine blade, and the functional surface is located at the end of the blade root section facing away from the intermediate section.

[0008] In some embodiments of this application, the functional surface has a gap with the flange body along the axial direction, a portion of the seal is accommodated in the gap, and another portion of the seal is located between the support surface and the peripheral surface of the flange body along the stacking direction.

[0009] In some embodiments of this application, the thickness of the protrusion is less than or equal to the thickness of the flange body along the axial direction.

[0010] On the other hand, this application also provides a wind turbine blade forming mold assembly, including a main body, a protrusion, and a seal. The main body extends along the axial direction of the wind turbine blade and bends around the blade in the circumferential direction to form a cavity. The protrusion protrudes from the functional surface of the main body along the axial direction. The seal is disposed on the supporting surface of the protrusion close to the cavity along its own thickness direction. The seal extends from one end of the main body along the circumferential direction to the other end along its own length direction and is used to seal between the functional surface and the blade root flange structure.

[0011] On the other hand, this application embodiment also provides a wind turbine blade forming method, including: providing a first forming mold assembly, the first forming mold assembly including a main body, a protrusion and a sealing member, the main body being bent and enclosed along the circumferential direction of the wind turbine blade to form a cavity, the protrusion being protruding and disposed on the functional surface of the main body along the axial direction of the wind turbine blade, the sealing member being disposed on the supporting surface of the protrusion near the cavity, and the sealing member extending along its own length from one end of the main body along the circumferential direction to the other end; forming a wind turbine blade shell structure on the first forming mold assembly, the shell structure and the blade root flange structure being matched, the blade root flange structure being installed on one side of the first forming mold assembly along the axial direction, along the axial direction, a portion of the blade root flange structure being opposite to the functional surface, and the peripheral side surface of the blade root flange structure abutting against the side of the sealing member facing away from the protrusion; vacuum-injecting a matrix material into the shell structure and curing it to obtain a wind turbine blade shell.

[0012] In some embodiments of this application, the step of forming the shell structure of a wind turbine blade on a molding die assembly includes: laying a skin layer on a first molding die assembly; installing a blade root preform on the skin layer along the stacking direction of the wind turbine blade, the blade root preform including a blade root layer structure and a blade root flange structure, a portion of the blade root flange structure being embedded in the blade root layer structure; and laying the remaining layer structure of the wind turbine blade, the remaining layer structure including at least a main beam and a core material.

[0013] In some embodiments of this application, the step of installing the blade root preform onto the skin layer includes: providing a second molding die assembly, the second molding die assembly including a main body, a protrusion, and a seal; laying a portion of the blade root layer structure on the second molding die assembly along the stacking direction of the wind turbine blade; installing a blade root flange structure having at least some pre-embedded bolts onto a portion of the blade root layer structure along the stacking direction, such that the blade root flange structure is installed on one side of the second molding die assembly along the axial direction, with a portion of the blade root flange structure facing the functional surface along the axial direction, and the peripheral side of the blade root flange structure abutting against the side of the seal facing away from the protrusion; laying the remaining layer structure of the blade root and the remaining portion of the pre-embedded bolt structure to form the blade root layer structure; and vacuum-infusing the blade root layer structure with matrix material and curing it to obtain the blade root preform.

[0014] In some embodiments of this application, before vacuum-infusing the matrix material into the leaf root layer structure, a sealing film is further included in the circumferential coating of the seal.

[0015] In some embodiments of this application, the step of forming the shell structure of a wind turbine blade on a molding die assembly includes: laying an outer skin layer on a first molding die assembly; laying a portion of a blade root layer structure on the first molding die assembly along the stacking direction of the wind turbine blade; installing a blade root flange structure having at least some pre-embedded bolts on a portion of the blade root layer structure along the stacking direction, such that the blade root flange structure is installed on one side of the first molding die assembly along the axial direction, and along the axial direction, a portion of the blade root flange structure is opposite to the functional surface, and the peripheral side of the blade root flange structure abuts against the side of the seal facing away from the protrusion; laying the remaining layer structure of the wind turbine blade, the remaining layer structure including at least the remaining layer structure of the blade root, the main beam, the core material and the blade tip layer structure, and the inner skin layer.

[0016] The wind turbine blade forming assembly, forming mold assembly, and forming method of this application embodiment feature a protruding portion on the axial functional surface of the first forming mold for mounting a sealing element. During installation of the blade root flange structure and the first forming mold, the peripheral side of the flange body of the blade root flange structure abuts against the sealing element, thereby forming a seal between the functional surface of the forming mold and the blade root flange structure, facilitating vacuum injection molding of the wind turbine blade. Furthermore, when the blade root flange structure presses the sealing element along the stacking direction, the protruding portion provides support for the sealing element, reducing the shearing effect of the blade root flange structure on the sealing element and ensuring the integrity and sealing effect of the sealing element. Attached Figure Description

[0017] 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.

[0018] Figure 1This is an axial cross-sectional view of a wind turbine blade forming assembly according to some embodiments of this application;

[0019] Figure 2 An example is shown. Figure 1 A magnified view of a portion of region A in the middle;

[0020] Figure 3 An example is shown. Figure 1 A schematic diagram of the molding die in the diagram;

[0021] Figure 4 Show Figure 3 A cross-sectional view along the axial direction of the molding die with the sealing element installed;

[0022] Figure 5 Another example is shown Figure 1 A schematic diagram of the molding die in the diagram;

[0023] Figure 6 Show Figure 5 A cross-sectional view along the axial direction of the molding die with the sealing element installed;

[0024] Figure 7 Show Figure 1 A schematic diagram of the blade root flange structure in the diagram;

[0025] Figure 8 Show Figure 7 A schematic diagram of the flange body in the diagram;

[0026] Figure 9 This is a flowchart of a wind turbine blade forming method according to some embodiments of this application;

[0027] Figure 10 This is another flowchart of a wind turbine blade forming method according to some embodiments of this application;

[0028] Figure 11 This is yet another flowchart of a wind turbine blade forming method according to some embodiments of this application;

[0029] Figure 12 This is another flowchart illustrating a wind turbine blade forming method according to some embodiments of this application.

[0030] Figure label:

[0031] 100. Blade root layer structure; 200. Blade root flange structure; 201. Peripheral side; 202. Outer contour curve; 210. Flange body; 211. Leading edge end; 212. Last edge end; 220. Embedded bolt; 230. Support leg; 300. Forming mold; 301. Functional surface; 302. Cavity; 303. Supporting surface; 310. Main body; 311. Cavity part; 312. End; 320. Protrusion; 400. Seal; 410. First sealing part; 420. Second sealing part; L. Vertical virtual line; X. Stacking direction; Z. Axial direction. Detailed Implementation

[0032] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.

[0033] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0034] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0035] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0036] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0037] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0038] In the description of the embodiments in this application, the technical terms "center," "longitudinal," and "lateral" are used.

[0039] Length, Width, Thickness, Top, Bottom, Front, Back, Left, Right

[0040] "Vertical", "Horizontal", "Top", "Bottom", "Inner", "Outer", "Clockwise", "Counterclockwise"

[0041] The orientation or positional relationship indicated by "axial", "radial", "circumferential", etc., is based on the orientation or positional relationship shown in the accompanying drawings and is only for the purpose of facilitating the description of the embodiments of this application and simplifying the description. It is not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the embodiments of this application.

[0042] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0043] Wind turbine blades are key components in wind turbine generators that convert wind energy into mechanical energy. They are typically made of composite materials and feature specific airfoils and structures to achieve efficient wind energy capture. During the blade molding process, reinforcing materials such as glass fiber are laid on a mold, and bolts are pre-embedded at the blade root. These bolts are connected and positioned via a flange structure. The flange structure is located on the blade root side of the mold, with its end face fitting snugly against the mold's end face. During vacuum injection of the wind turbine blade, a seal must be maintained between the flange structure and the mold's end face to facilitate overall vacuuming and resin injection of the wind turbine blade.

[0044] In related technologies, a sealing strip is bonded to the end face of the blade root side of the mold, and a flange structure is installed onto the mold along the axial direction of the wind turbine blade. The end face of the flange structure is pressed against the sealing strip to achieve a seal. However, axial installation of the flange structure can damage the fiber layer structure already laid on the mold. As the flange structure moves axially toward the sealing strip, the pre-embedded bolts on the flange structure can easily touch the laid fiber layer, causing the fiber layer to curl or tear, thus affecting the integrity and flatness of the wind turbine blade's layer structure.

[0045] If a flange structure is installed from top to bottom along the vertical and axial directions, although damage to the already laid fiber layer is reduced, the flange structure will shear the sealing strip during its downward movement after contact with the sealing strip. This can cause the sealing strip to partially peel off or fall out of the mold, thus affecting the sealing performance between the flange structure and the mold, and consequently affecting the forming quality of the wind turbine blade.

[0046] In view of this, the present application provides a wind turbine blade forming assembly, a forming mold assembly, and a forming method. By providing a protrusion protruding from the main body of the forming mold on the blade root side, and providing a sealing element on the side of the protrusion facing the upper blade root flange structure, the protrusion supports the sealing element when the blade root flange structure is constructed in a direction perpendicular to the axial direction. This reduces the risk of partial peeling or detachment caused by the shearing of the sealing element by the blade root flange structure, improves the sealing performance between the blade root flange structure and the forming mold, and thus improves the forming quality of the wind turbine blade.

[0047] like Figures 1 to 8 This application provides a wind turbine blade forming assembly, including a blade root layer structure 100, a blade root flange structure 200, a forming mold 300, and a sealing element 400. The blade root flange structure 200 includes a flange body 210 and pre-embedded bolts 220 installed on the flange body 210. Along the axial direction Z of the wind turbine blade, the pre-embedded bolts 220 are located on one side of the flange body 210. Along the stacking direction X, the pre-embedded bolts 220 are located inside the blade root layer structure 100. The flange body 210 is located at one end of the blade root layer structure 100 along the axial direction Z. The forming mold 300 includes a main body 310 and a protrusion 320. The main body 310 is located along the circumference of the wind turbine blade. The body is bent to form a cavity 302. A protrusion 320 protrudes from the functional surface 301 of the main body 310 along the axial direction Z. A blade root layer structure 100 is laid in the cavity 302. A blade root flange structure 200 is installed on the forming mold 300. Along the axial direction Z, part of the flange body 210 is opposite to the functional surface 301. A sealing element 400 is disposed on the support surface 303 of the protrusion 320 near the cavity 302 along the stacking direction X. The sealing element 400 extends from one end of the main body 310 along the circumferential direction along its own length direction to the other end. The peripheral side surface 201 of the flange body 210 abuts against the side of the sealing element 400 facing away from the protrusion 320.

[0048] The blade root layer structure 100 is a layered structure near the root of the wind turbine blade, usually made of multiple layers of composite materials, which provides structural strength for the wind turbine blade and a connection base with the blade root flange structure 200.

[0049] For example, composite materials can be glass fiber, carbon fiber, etc., which have high strength and stiffness and can provide the necessary structural support for wind turbine blades.

[0050] The blade root flange structure 200 is used to connect the wind turbine blade and the wind turbine hub, and includes a flange body 210 and embedded bolts 220. The flange body 210 serves as a connection and support, and the embedded bolts 220 are used to strengthen the connection with the blade root layer structure 100.

[0051] For example, the flange body 210 can be made of a metallic material with a certain thickness and strength. In one example, the flange body 210 is semi-circular, and a wind turbine blade has two semi-circular flange bodies 210, which are interlocked to form a circle. Each semi-circular flange body 210 matches the windward or leeward shell.

[0052] For example, the pre-embedded bolts 220 include a plurality of bolts, and the plurality of pre-embedded bolts 220 are installed on the flange body 210 at equal angles along the circumference of the flange body 210.

[0053] Along the axial direction Z of the wind turbine blade, a pre-embedded bolt 220 is connected through the flange body 210, and the side of the pre-embedded bolt 220 closer to the blade root layer structure 100 is longer than the other side away from the blade root layer structure 100, so as to facilitate pre-embedding in the blade root layer structure 100.

[0054] In the X-direction of the stacking process, the pre-embedded bolts 220 are located within the blade root layer structure 100. After curing, they are firmly bonded to the blade root layer structure 100, enabling a stable connection between the blade root layer structure 100 and the blade root flange structure 200. The flange body 210 is located at one end of the blade root layer structure 100 along the Z-axis, serving to connect the wind turbine blades and the wind turbine hub.

[0055] The forming mold 300 is used to form the wind turbine blade during the manufacturing process. Exemplarily, the forming mold 300 is used to form the windward or leeward shell of the wind turbine blade. In some embodiments, the forming mold 300 is used only to form the blade root pre-embedded part.

[0056] The molding die 300 includes a main body 310 and a protrusion 320. The main body 310 is bent and enclosed along the circumferential direction of the wind turbine blade to form a cavity 302. The shape and size of the cavity 302 are precisely designed according to the design requirements of the wind turbine blade and are used to lay the blade root layer structure 100. The shape of the cavity 302 at least partially matches the blade root portion.

[0057] In some examples, the shell's layered structure is laid within the cavity 302, the shape of which matches the shell of the wind turbine blade.

[0058] In one example, the main body 310 includes a cavity portion 311 and an end portion 312 connected together. The cavity portion 311 extends along the axial direction Z, and the end portion 312 is located at one end of the cavity portion 311 along the axial direction Z. A protrusion 320 is provided on the side of the end portion 312 facing away from the cavity portion 311. The side of the end portion 312 facing away from the cavity portion 311 is a functional surface 301, and the cavity portion 311 is bent in the circumferential direction to form a cavity 302.

[0059] For example, the main body 310 includes a functional surface 301 and a first end face disposed opposite each other along the axial direction Z. As an example, the shape of the functional surface 301 is similar to a torus.

[0060] The leaf root flange structure 200 is installed on the forming mold 300. Exemplarily, the flange body 210 is placed on one side of the functional surface 301, and the functional surface 301 is used to limit the flange body 210 along the axial direction Z. In one example, the flange body 210 is connected to the forming mold 300 by a detachable connection method such as bolting or snap-fitting.

[0061] Part of the flange body 210 is opposite to the functional surface 301. For example, the flange body 210 has radially embedded bolts 220 on the side facing away from the blade root layer structure 100 opposite to the functional surface 301. After the wind turbine blade is formed, the flange body 210 needs to be removed, and the embedded bolts 220 are left inside the wind turbine blade.

[0062] The protrusion 320 protrudes from the functional surface 301 of the main body 310 along the Z-axis. Exemplarily, the protrusion 320 may be integrally formed with the main body 310 or separately connected. In some examples, the protrusion 320 may be strip-shaped. In another example, the protrusion 320 is provided on the main body 310 in the form of a boss. In other embodiments, the protrusion 320 may be one or more segments along the circumference of the flange body 210.

[0063] In one example, the width of the protrusion 320 along the axial direction Z ranges from 10 to 30 mm. For example, the width of the protrusion 320 is a range consisting of one or two of the following: 10 mm, 15 mm, 18 mm, 20 mm, 21 mm, 25 mm, 28 mm, and 30 mm.

[0064] The protrusion 320 includes a support surface 303 located near one end of the cavity 302 along the lamination direction X. Exemplarily, the support surface 303 can be a flat surface, a sloped surface, or a curved surface. In one example, a recess may be formed on the support surface 303 to facilitate the recess of the seal 400 to limit the movement of the seal 400 along the axial direction Z.

[0065] Seal 400 is a component with a sealing function used to prevent material leakage during the molding process and ensure the molding quality of wind turbine blades. For example, seal 400 is made of elastic materials such as butyl rubber and rubber strips, possessing elasticity and flowability.

[0066] The seal 400 is disposed on the raised support surface 303. For example, the raised support abuts against the seal 400, or the raised is connected to the seal 400 by means of bonding, snap-fitting, riveting, etc.

[0067] The seal 400 extends circumferentially from one end of the main body 310 to the other along its length, meaning that the seal 400 is a continuous structure to ensure a circumferential sealing effect on the flange body 210. In other words, the seal 400 extends continuously from the front edge to the rear edge of the forming mold 300.

[0068] In one example, the seal 400 has a width of 20 mm along the axial direction Z and a thickness of 10 mm along the stacking direction X.

[0069] The peripheral side 201 of the flange body 210 abuts against the side of the seal 400 facing away from the protrusion 320. Exemplarily, the outer contour of the peripheral side 201 of the flange body 210 can be arc-shaped or a semi-arc-shaped shape with protrusions. In one example, the outer contour curve 202 of the flange body 210 extends from the leading edge 211 to the trailing edge 212. The outer contour curve 202 does not intersect with any vertical virtual line L along the stacking direction X, thus preventing interference between the flange body 210 and the protrusion 320 during its descent. As an example, the outer contour of the flange body 210 is semi-circular.

[0070] In another example, the leaf root flange structure 200 includes a leg 230 mounted on the side of the flange body 210 facing away from the forming mold 300. The leg 230 protrudes radially from the flange body 210. The axial Z-width of the protrusion 320 is less than or equal to the thickness of the flange body 210.

[0071] By providing a protruding portion 320 along the Z-axis functional surface 301 of the forming mold 300 for mounting the seal 400, when the blade root flange structure 200 is installed with the forming mold 300, the peripheral side surface 201 of the flange body 210 of the blade root flange structure 200 abuts against the seal 400, thereby forming a seal between the functional surface 301 of the forming mold 300 and the blade root flange structure 200, facilitating the vacuum injection molding of the wind turbine blade. Furthermore, when the blade root flange structure 200 extrudes the seal 400 along the X-layer direction, the protruding portion 320 provides support for the seal 400, reducing the shearing effect of the blade root flange structure 200 on the seal 400 and ensuring the integrity and sealing effect of the seal 400.

[0072] In an optional embodiment of this application, the main body 310 includes a blade root segment for laying blade root preforms.

[0073] The blade root preform is the initial forming component at the root of the wind turbine blade. Through the design of the blade root section, the shape and size of the blade root preform can be controlled more precisely. The shape and structure of the blade root section are optimized according to the design requirements of the blade root preform, so that the formed blade root preform can better fit with the blade root layer structure 100 and the blade root flange structure 200.

[0074] During the manufacturing process, the blade root layer structure 100 is laid within the cavity 302 formed by the blade root section. After curing and other processes, a blade root preform that meets the requirements is formed. This improves the forming quality of the blade root preform and further enhances the overall performance of the wind turbine blade.

[0075] In another embodiment of this application, the main body 310 includes a blade root section, an intermediate section and a blade tip section arranged sequentially along the Z-axis for forming the shell of the wind turbine blade, and the functional surface 301 is located at the end of the blade root section facing away from the intermediate section.

[0076] The blade root section, intermediate section, and blade tip section enable the forming mold 300 to form the windward or leeward shell of the wind turbine blade in one step, improving production efficiency. The functional surface 301 is located at the end of the blade root section away from the intermediate section, which facilitates the installation and assembly of the blade root layer structure 100 and the blade root flange structure 200.

[0077] During the manufacturing process, the blade root layer structure 100 is laid in the cavity 302 of the blade root section, and the cavities 302 of the middle section and the blade tip section are used to lay other composite material layers. Through the integral molding method, the integrity and continuity of the wind turbine blade shell can be guaranteed, the structural weaknesses caused by splicing are reduced, and the strength and reliability of the wind turbine blade are improved.

[0078] In one embodiment of this application, along the axial direction Z, the functional surface 301 has a gap with the flange body 210, a portion of the seal 400 is accommodated in the gap, and along the stacking direction X, another portion of the seal 400 is located between the support surface 303 and the peripheral side surface 201 of the flange body 210.

[0079] For example, when the flange body 210 is mounted on the molding die 300, the sealing element 400 includes a first sealing portion 410 and a second sealing portion 420. The first sealing portion 410 extends along the axial direction Z, and the second sealing portion 420 extends along the stacking direction X. The second sealing portion 420 protrudes from the first sealing portion 410 along the stacking direction X. The first sealing portion 410 fills the space between the outer peripheral surface of the flange body 210 and the protrusion, and the second sealing portion 420 fills the space between the functional surface 301 and one end face of the flange body 210 along the axial direction Z.

[0080] In one example, the gap between the functional face 301 and the flange body 210 ranges from 1 to 10 mm. For example, the gap is one or two of the following: 1 mm, 2 mm, 5 mm, 6 mm, 8 mm, and 10 mm.

[0081] During the substrate injection process, the gap between the functional surface 301 and the end face of the flange body 210 allows the liquid substrate to overflow from the blade root layer structure 100, thus ensuring that the blade root layer structure 100 is fully wetted with the liquid substrate and improving the injection effect. Furthermore, the sealing element 400 provides sealing in both the axial direction (Z) and the lamination direction (X), and extends the sealing length, further enhancing the sealing effect. Additionally, product demolding is easier, reducing damage to the mold during demolding.

[0082] Furthermore, in one embodiment of this application, the thickness of the protrusion 320 along the axial direction Z is less than or equal to the thickness of the flange body 210. This facilitates the fit between the blade root flange structure 200 and the protrusion, and avoids interference between the protrusion and the blade root flange structure 200, for example, avoiding interference with the support leg 230.

[0083] In one embodiment, the wind turbine blade forming assembly further includes a sealing film connected to the seal 400 and the forming mold 300 for covering the seal 400.

[0084] For example, the width of the sealing film ranges from 20 to 100 mm. As an example, the sealing film can be a plastic film used to prevent the seal 400 from creeping under vacuum force when the cavity 302 of the molding die 300 is under vacuum, thus preventing air leakage.

[0085] like Figures 1 to 12 As shown in the embodiment of this application, a wind turbine blade forming mold assembly is also provided, including a main body 310, a protrusion 320, and a seal 400. The main body 310 extends along the axial direction Z of the wind turbine blade and bends along the circumferential direction of the wind turbine blade to form a cavity 302. The protrusion 320 protrudes from the functional surface 301 of the main body 310 along the axial direction Z. The seal 400 is disposed on the supporting surface 303 of the protrusion 320 near the cavity 302 along its own thickness direction. The seal 400 extends from one end of the main body 310 along the circumferential direction along its own length direction to the other end, and is used to seal between the functional surface 301 and the blade root flange structure 200.

[0086] This application also provides a wind turbine blade forming method, including steps S1 to S3. The wind turbine blade forming method of this application is implemented using the wind turbine blade forming mold assembly of the above embodiments.

[0087] S1: Provide a first molding die assembly, which includes a main body 310, a protrusion 320 and a seal 400. The main body 310 is bent and enclosed along the circumferential direction of the wind turbine blade to form a cavity 302. The protrusion 320 protrudes from the functional surface 301 of the main body 310 along the axial direction Z of the wind turbine blade. The seal 400 is disposed on the support surface 303 of the protrusion 320 near the cavity 302. The seal 400 extends along its own length from one end of the main body 310 along the circumferential direction to the other end.

[0088] For example, the first molding die assembly can be obtained by assembling finished products or by subsequent assembly of individual units. The shape of the main body 310 of the first molding die assembly matches the shape of the windward or leeward shell of the wind turbine blade.

[0089] S2: A shell structure for a wind turbine blade is formed on the first forming mold assembly. The shell structure and the blade root flange structure 200 are matched. The blade root flange structure 200 is installed on one side of the first forming mold assembly along the axial direction Z. Along the axial direction Z, a portion of the blade root flange structure 200 is opposite to the functional surface 301. The peripheral side surface 201 of the blade root flange structure 200 abuts against the side of the seal 400 facing away from the protrusion 320.

[0090] After the molding die assembly is prepared, the shell structure of the wind turbine blade begins to be formed on it. The shell structure and the blade root flange structure 200 are matched. First, several layers of reinforcing material are laid in the cavity 302 of the main body 310. For example, the reinforcing material can be glass fiber, carbon fiber, etc. The layers are laid in a preset sequence and angle to ensure that the shell structure has sufficient strength and rigidity. After the reinforcing material is laid, it is initially compacted and fixed to prepare for the subsequent installation of the blade root flange structure 200. The first molding die assembly is the molding die 300.

[0091] The blade root flange structure 200 is installed on one side of the first forming mold assembly along the Z-axis. The blade root flange structure 200 is placed on the Z-axis side of the first forming mold assembly, and its position is adjusted so that the circumferential side 201 of the flange body 210 is in close contact with the side of the seal 400 facing away from the protrusion 320. The pre-embedded bolts 220 of the blade root flange structure 200 are placed on top of the laid reinforcing material for pre-embedding preparation. To ensure installation accuracy, positioning devices such as locating pins and guide blocks can be used to position the blade root flange structure 200.

[0092] After positioning, the blade root flange structure 200 is fixed to the forming mold assembly by fastening devices such as bolts and pressure plates. Appropriate pressure is applied so that the peripheral side 201 of the flange body 210 fully abuts against the sealing element 400, thereby forming a seal between the functional surface 301 of the forming mold 300 and the blade root flange structure 200.

[0093] During installation, it is necessary to control the degree of compression of the blade root flange structure 200 along the stacking direction X to avoid excessive compression that could damage the seal 400, while also ensuring sufficient compression to guarantee the sealing effect. The support provided by the protrusion 320 to the seal 400 effectively disperses the pressure exerted by the blade root flange structure 200 on the seal 400, reduces shear force, and protects the integrity of the seal 400.

[0094] After the blade root flange structure 200 is installed, the remaining reinforcing material is laid in the cavity 302 to complete the overall laying of the shell structure and the pre-embedding of the bolts 220. During the laying process, it is essential to ensure a tight bond between the reinforcing material and the pre-embedded bolts 220 to avoid defects such as delamination and air bubbles. Simultaneously, the laid reinforcing material is further compacted and trimmed to ensure that the shape and dimensions of the shell structure meet the design requirements.

[0095] S3: Vacuum infusion of matrix material into the shell structure and curing to obtain the wind turbine blade shell.

[0096] Before vacuum-injecting the matrix material into the shell structure, a vacuum injection system is laid on the shell structure to inject the matrix material into the cavity 302 of the molding mold 300 in a vacuum environment, so that the matrix material fully impregnates the reinforcing material and forms a complete shell structure.

[0097] For example, the vacuum infusion system includes a vacuum pump, a resin tank, pipes, etc. The shell structure can be evacuated while the matrix material is being infused, or a partial vacuum can be evacuated and infused separately, or a vacuum can be evacuated first and then infused.

[0098] For example, the matrix material is usually a resin, such as epoxy resin or unsaturated polyester resin. A suitable matrix material is selected according to actual needs and mixed in accordance with the specified ratio.

[0099] In one example, firstly, the first molding die assembly is connected to the vacuum infusion equipment, and the vacuum pump is turned on to evacuate the cavity 302 until the vacuum level reaches the set value. Under vacuum, the air in the cavity 302 is extracted, creating favorable conditions for the injection of the matrix material. Then, the valve of the resin tank is opened, allowing the prepared matrix material to be slowly injected into the cavity 302 through the pipeline under vacuum pressure. During injection, the injection speed must be controlled to avoid excessively fast injection, which could lead to air bubbles or material overflow. Simultaneously, the resin flow is observed to ensure that the resin evenly wets the entire shell structure, including the sealing area between the blade root flange structure 200 and the molding die assembly. When resin overflows from the mold's outlet, it indicates that the cavity 302 is full of resin. At this point, the valve of the resin tank and the vacuum pump are closed, completing the vacuum infusion process.

[0100] In one example, after vacuum infusion, the shell structure needs to be cured to allow the base material to undergo a chemical reaction, forming a hard solid, thus obtaining the wind turbine blade shell. The curing process is typically carried out under specific temperature and time conditions. Appropriate curing temperatures and times are set based on the characteristics of the base material. During curing, the first molding die assembly needs to be kept warm to ensure uniform temperature distribution and avoid problems such as internal stress or incomplete curing caused by temperature differences. After curing, once the shell structure has cooled to room temperature, the first molding die assembly and flange body 210 can be removed, and the wind turbine blade shell can be taken out.

[0101] By providing a protruding portion 320 along the Z-axis functional surface 301 of the molding die 300 for mounting the seal 400, when the blade root flange structure 200 is installed with the molding die 300, the peripheral side surface 201 of the flange body 210 of the blade root flange structure 200 abuts against the seal 400, thereby forming a seal between the functional surface 301 of the molding die 300 and the blade root flange structure 200. This sealing structure can effectively prevent air from entering and resin from leaking during vacuum infusion, providing a good sealing environment for the vacuum infusion molding of wind turbine blades. At the same time, when the blade root flange structure 200 extrudes the seal 400 along the X-layer direction, the protruding portion 320 provides solid support for the seal 400, reducing the shear force of the blade root flange structure 200 on the seal 400, avoiding damage to the seal 400 due to excessive shear force, ensuring the integrity and sealing effect of the seal 400, thereby improving the molding quality and production efficiency of the wind turbine blade.

[0102] When forming large base circle wind turbine blades, the diameter of the blade root pitch circle can reach over 3 meters, and the total blade length can reach hundreds of meters, making the blade forming process quite challenging. To reduce the manufacturing difficulty, the formed blade root preform is installed in a mold to form the wind turbine blade shell. However, the weight of the formed blade root preform far exceeds that of the flange body 210, making sealing even more difficult.

[0103] In an optional embodiment of this application, step S2, which involves forming the shell structure of the wind turbine blade on the first molding die assembly, includes steps S21 to S23.

[0104] S21: Lay a skin layer on the first molding die assembly.

[0105] The skin layer, as the outer structure of the wind turbine blade shell, serves to protect the internal structure and optimize aerodynamic performance. For example, before laying the skin layer, the surface of the cavity 302 of the first molding die assembly needs to be cleaned and demolded, and a release agent needs to be applied to ensure a smooth demolding process.

[0106] As an example, the skin layer can be made of glass fiber fabric or carbon fiber fabric, and the appropriate fabric specifications and layup method can be selected according to the design requirements of the blade.

[0107] In one example, the cut skin layer fabric is laid sequentially on the surface of cavity 302. During the laying process, attention should be paid to the smoothness of the fabric to avoid wrinkles and air bubbles. Using a special pressure roller tool, the skin layer fabric is gradually pressed from one end of cavity 302 to the other to make the fabric fit tightly against the mold surface, while expelling the air between the fabric and the mold.

[0108] S22: Along the stacking direction X of the wind turbine blade, install the blade root prefabricated component on the skin layer. The blade root prefabricated component includes the blade root layer structure 100 and the blade root flange structure 200. Part of the blade root flange structure 200 is embedded in the blade root layer structure 100.

[0109] The embedded bolts of the blade root flange structure 200 in the blade root prefabrication are key components for the connection between the wind turbine blade and the hub. For example, the embedded bolts 220 of the blade root flange structure 200 are embedded in the blade root layer structure 100.

[0110] In one example, the blade root preform is placed at a predetermined position on the skin layer and installed along the stacking direction X of the wind turbine blade. During installation, positioning devices such as locating pins and guide grooves are used to ensure that the installation position of the blade root preform is accurate. The blade root flange structure 200 corresponds to the functional surface 301 of the first forming mold assembly along the axial direction Z, and its peripheral side surface 201 abuts against the seal 400.

[0111] For example, in order to enhance the bonding force between the leaf root preform and the skin layer, an appropriate amount of resin adhesive can be applied to the surfaces in contact with the two, and subsequent operations can be carried out after the resin adhesive has initially cured.

[0112] S23: The remaining layer structure for laying wind turbine blades, which includes at least the main beam, core material and blade tip layer structure.

[0113] The main beam is the main load-bearing component of the wind turbine blade. For example, the main beam can be made of high-strength carbon fiber or glass fiber reinforced composite material.

[0114] In one example, the layup sequence and angle of the main beam are determined, and the cut main beam material is laid sequentially on the blade root prefabricated component and the skin layer according to the design requirements. During the laying process, it is essential to ensure that the fiber direction of the main beam material is consistent with the stress direction of the blade to fully utilize the material's strength properties. After each layer of main beam material is laid, it is also compacted using a pressure roller to ensure a tight fit between the materials.

[0115] The core material is used to improve the structural stability of the blade and reduce its weight. Examples of core materials include foam core materials, balsa wood core materials, etc. After being cut to the designed shape and size, the core material is installed in the corresponding positions on the blade. Examples of core materials include those laid between the main beams, and in the aerodynamic profile parts of the blade.

[0116] In one example, the core material is bonded and fixed to the surrounding material with resin adhesive to ensure that the core material does not shift during the molding process.

[0117] The tip layer structure has a significant impact on the aerodynamic performance of the blade, and its materials and layup methods are similar to those of the skin layer. For example, pre-cut tip layer structure material is laid on the tip of the blade, ensuring that the tip's shape meets design requirements.

[0118] In this embodiment, the wind turbine blade is formed by using a blade root prefabrication method. When the blade root flange structure 200 compresses the sealing element 400 along the stacking direction X, the protrusion 320 provides solid support for the sealing element 400, reducing the sealing difficulty.

[0119] In one embodiment of this application, the step of installing the leaf root preform onto the skin layer in step S22 includes steps S221 to S225.

[0120] S221: Provide a second molding die assembly.

[0121] The second forming mold assembly is structurally similar to the first forming mold assembly in step S1, also including a main body 310, a protrusion 320, and a seal 400. Its function is specifically to prepare the blade root preform, providing precise forming space for the assembly of the blade root layer structure 100 and the blade root flange structure 200. The size and shape of this mold assembly are customized according to the design requirements of the blade root preform, ensuring accurate forming of blade root preforms that meet specifications.

[0122] S222: Along the stacking direction X of the wind turbine blade, a portion of the blade root layer structure 100 is laid on the second forming mold assembly.

[0123] On the second molding die assembly for preparing the blade root preform, a portion of the blade root layer structure 100 is first laid. In one example, the blade root layer structure 100 may be composed of multiple layers of reinforcing fiber material; for example, the reinforcing fiber material may be glass fiber, carbon fiber, etc.

[0124] In another example, the reinforcing fiber material is cut and pre-treated according to design requirements before laying. During the laying process, the predetermined layering sequence and angle are strictly followed to ensure that the fiber direction matches the stress direction of the blade root in the wind turbine blade, thereby improving the load-bearing capacity of the blade root. After laying, this part of the blade root layer structure 100 is initially compacted to remove interlayer air and ensure a tight bond between layers.

[0125] S223: Along the stacking direction X, a blade root flange structure 200 with at least some pre-embedded bolts 220 is installed on a portion of the blade root layer structure 100, such that the blade root flange structure 200 is installed on one side of the second forming mold assembly along the axial direction Z. Along the axial direction Z, a portion of the blade root flange structure 200 is opposite to the functional surface 301, and the peripheral side surface 201 of the blade root flange structure 200 abuts against the side of the seal 400 facing away from the protrusion 320.

[0126] For example, the blade root flange structure 200 has at least some pre-embedded bolts 220 for subsequent connection to the hub. The blade root flange structure 200 may install some or all of the pre-embedded bolts 220. The second forming die assembly may be a forming die 300.

[0127] As an example, the blade root flange structure 200 is lifted approximately vertically (i.e., in the stacking direction X) above the molding die 300 using a hoisting tool, and then slowly lowered to a designated position using a guide mechanism. Upon descent, the seal 400 is compressed and deformed, overflowing to complete the seal between the blade root flange structure 200 and the molding die 300. This installation method utilizes the seal 400 to achieve a seal between the blade root flange structure 200 and the second molding die assembly, providing a good sealing environment for the subsequent vacuum infusion process. Simultaneously, the supporting effect of the protrusion 320 effectively reduces the shear force exerted by the blade root flange structure 200 on the seal 400, ensuring the integrity and sealing effect of the seal 400.

[0128] S224: Lay the remaining layer structure of the leaf root and the remaining pre-embedded bolts to form the leaf root layer structure 100.

[0129] After the blade root flange structure 200 is installed, the remaining blade root layer structure is laid. The material and layup method of the remaining layer structure are similar to those of the previously laid portion of the blade root layer structure 100.

[0130] S225: Vacuum infusion of matrix material into the leaf root layer structure and curing to obtain the leaf root preform.

[0131] After the leaf root layer structure 100 is laid, it is vacuum-infused with matrix material.

[0132] In one example, firstly, the entire second molding die assembly is sealed to ensure no air leakage occurs in a vacuum environment. Then, a vacuum pump is used to evacuate the air from cavity 302, creating a vacuum environment. Under vacuum, a prepared matrix material (such as epoxy resin) is injected into the blade root layer structure 100 through a pouring system, ensuring the matrix material fully impregnates the reinforcing fiber material. During pouring, the pouring speed and pressure are carefully controlled to ensure the matrix material uniformly fills the entire blade root layer structure 100. After pouring, the second molding die assembly is heated and kept at a constant temperature according to the matrix material's curing process requirements, causing the matrix material to cure and form a hard solid. After curing, the material is cooled to room temperature, and the molding die assembly is removed to obtain the blade root preform containing the blade root layer structure 100 and the blade root flange structure 200.

[0133] In some embodiments of this application, before vacuum infusing the substrate material into the leaf root layer structure 100 in step S225, the method further includes: circumferentially covering the sealant 400 with a sealing film.

[0134] For example, the sealing membrane can be a high-temperature resistant and resin-permeable polytetrafluoroethylene (PTFE) membrane or a silicone rubber membrane, which has good flexibility and tear resistance, ensuring that the elastic deformation of the seal 400 is not affected after covering.

[0135] As an example, the thickness of the sealing film can be 0.1-0.3 mm.

[0136] For example, the membrane material covers the contact interface between the seal 400 and the flange peripheral side 201, as well as the joint edge between the seal 400 and the support surface 303 of the protrusion 320, along the circumferential direction of the seal 400 (i.e., the annular area between the two ends of the mold), ensuring that the membrane material completely covers the exposed portion of the seal 400.

[0137] In one example, starting from one end of the molding die 300, the sealing film is tightly wrapped around the outside of the seal 400 circumferentially. While wrapping, a tool (such as a plastic scraper) is used to press the film onto the surface of the seal 400 to eliminate wrinkles or air bubbles. The two ends of the film are fixed with high-temperature resistant tape in the non-functional areas of the mold (such as the mold body outside the protrusion 320) to prevent the film from shifting during injection.

[0138] A sealing membrane is used to cover the seal 400. During vacuum injection, the sealing membrane blocks the penetration path of the matrix material into the gap between the seal 400 and the mold functional surface 301, preventing the seal 400 from sticking to it after the resin cures, which would cause the seal 400 to tear or remain during demolding. The elastic fit between the sealing membrane and the seal 400 forms a composite sealing structure under the flange axial Z pressure, which compensates for the attenuation of the sealing performance of the seal 400 due to long-term use or deformation, and ensures the stability of the vacuum during the injection process.

[0139] In one specific embodiment of this application, the step of forming the shell structure of the wind turbine blade on the first molding die assembly in step S2 includes steps S201 to S204.

[0140] S201: Lay an outer skin layer on the first molding die assembly.

[0141] As the outermost structure of a wind turbine blade, the outer skin layer is in direct contact with the external environment and plays a crucial role in the blade's aerodynamic performance and weather resistance.

[0142] For example, a certain overlap width needs to be ensured between two adjacent outer skin layers. As an example, the overlap width is 5-10cm to enhance the interlayer connection strength.

[0143] S202: Along the stacking direction X of the wind turbine blade, a portion of the blade root layer structure 100 is laid on the first forming mold assembly.

[0144] After the outer skin layer is laid, a portion of the blade root layer structure 100 is laid along the stacking direction X of the wind turbine blade. The material of this portion of the blade root layer structure 100 is mainly a high-strength fiber-reinforced composite material, such as carbon fiber reinforced epoxy resin prepreg.

[0145] For example, 30%-0% of the total thickness of the blade root layer structure 100 is laid first to provide a suitable foundation for the subsequent installation of the blade root flange structure 200.

[0146] S203: Along the stacking direction X, a blade root flange structure 200 with at least some pre-embedded bolts 220 is installed on a portion of the blade root layer structure 100, such that the blade root flange structure 200 is installed on one side of the first forming mold assembly along the axial direction Z. Along the axial direction Z, a portion of the blade root flange structure 200 is opposite to the functional surface 301, and the peripheral side surface 201 of the blade root flange structure 200 abuts against the side of the seal 400 facing away from the protrusion 320.

[0147] The embedded bolts 220 on the blade root flange structure 200 are used to connect with the hub. The number, specifications and embedment depth of the bolts are strictly implemented in accordance with the design standards to ensure the reliability of the connection.

[0148] In one example, during installation, the blade root flange structure 200 is hoisted and slowly placed onto a portion of the pre-laid blade root layer structure 100 along the stacking direction X. Precise positioning is achieved using locating pins on the mold and locating holes on the flange structure, ensuring that the blade root flange structure 200 is installed on the side of the first forming mold assembly along the axial direction Z, with a portion of the blade root flange structure 200 facing the functional surface 301 along the axial direction Z. At this point, the peripheral side 201 of the blade root flange structure 200 tightly abuts against the side of the seal 400 facing away from the protrusion 320. Supported by the protrusion 320, the seal 400 undergoes elastic deformation, forming a good sealing effect and preventing resin leakage and air ingress during subsequent vacuum infusion. During installation, a torque wrench is used to tighten the connecting bolts to the specified torque value to ensure the blade root flange structure 200 is securely installed.

[0149] S204: Residual layer structure for laying wind turbine blades, the residual layer structure includes at least the residual layer structure at the blade root, main beam, core material and blade tip layer structure, and inner skin layer.

[0150] The inner skin layer, as a protective layer inside the blade, plays a role in protecting the internal structure and improving the overall strength of the blade. The laying process of the inner skin layer is similar to that of the outer skin layer. The cut inner skin layer fabric is laid inside the mold cavity 302, tightly bonded to other layers, and then compacted and cured to form a complete shell structure.

[0151] In one embodiment of this application, before vacuum-infusing the substrate material into the shell structure in step S3, the method further includes: circumferentially covering the seal 400 with a sealing film.

[0152] 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 forming assembly, characterized in that, include: Leaf root layer structure; The blade root flange structure includes a flange body and pre-embedded bolts installed on the flange body. Along the axial direction of the wind turbine blade, the pre-embedded bolts are located on one side of the flange body. Along the stacking direction, the pre-embedded bolts are located inside the blade root layer structure. The flange body is located at one end of the blade root layer structure along the axial direction. A molding die includes a main body and a protrusion. The main body is bent and enclosed along the circumferential direction of the wind turbine blade to form a cavity. The protrusion protrudes from the functional surface of the main body along the axial direction. The blade root layer structure is laid in the cavity. The blade root flange structure is installed in the molding die. Along the axial direction, a portion of the flange body is opposite to the functional surface. A sealing element is disposed on the support surface of the protrusion near the cavity along the stacking direction. The sealing element extends from one end of the main body along the circumferential direction to the other end along its own length direction. The peripheral side of the flange body abuts against the side of the sealing element facing away from the protrusion.

2. The wind turbine blade forming assembly according to claim 1, characterized in that, The main body includes a blade root section, a middle section and a blade tip section arranged sequentially along the axial direction, which are used to form the shell of the wind turbine blade. The functional surface is located at the end of the blade root section opposite to the middle section.

3. The wind turbine blade forming assembly according to claim 1, characterized in that, Along the axial direction, the functional surface has a gap with the flange body, a portion of the seal is accommodated in the gap, and along the stacking direction, another portion of the seal is located between the support surface and the peripheral surface of the flange body.

4. The wind turbine blade forming assembly according to claim 1, characterized in that, Along the axial direction, the thickness of the protrusion is less than or equal to the thickness of the flange body.

5. A wind turbine blade forming mold assembly, characterized in that, include: The main body extends along the axial direction of the wind turbine blade and bends and encloses the blade in the circumferential direction to form a cavity. A protrusion is provided on a functional surface of the main body along the axial direction. A sealing element is disposed on the support surface of the protrusion near the cavity along its own thickness direction. The sealing element extends from one end of the main body along the circumferential direction to the other end along its own length direction, and is used to seal the functional surface and the blade root flange structure.

6. A method for forming wind turbine blades, characterized in that, The method includes: A first molding die assembly is provided, the first molding die assembly includes a main body, a protrusion and a seal, the main body is bent and enclosed along the circumferential direction of the wind turbine blade to form a cavity, the protrusion is protruding and disposed on the functional surface of the main body along the axial direction of the wind turbine blade, and the seal is disposed on the supporting surface of the protrusion near the cavity, the seal extends along its own length from one end of the main body along the circumferential direction to the other end; A shell structure for a wind turbine blade is formed on the first molding die assembly. The shell structure and the blade root flange structure are matched. The blade root flange structure is installed on one side of the first molding die assembly along the axial direction. Along the axial direction, a portion of the blade root flange structure is opposite to the functional surface. The peripheral side of the blade root flange structure abuts against the side of the seal facing away from the protrusion. The shell structure is vacuum-injected with a matrix material and then cured to obtain the wind turbine blade shell.

7. The wind turbine blade forming method according to claim 6, characterized in that, The step of forming the shell structure of the wind turbine blade on the first molding die assembly includes: A skin layer is laid on the first molding die assembly; Along the stacking direction of the wind turbine blades, a blade root prefabricated component is installed on the skin layer. The blade root prefabricated component includes a blade root layer structure and a blade root flange structure, with a portion of the blade root flange structure embedded in the blade root layer structure. The remaining layer structure for laying wind turbine blades, wherein the remaining layer structure includes at least a main beam and a core material.

8. The wind turbine blade forming method according to claim 7, characterized in that, The step of installing the leaf root preform onto the skin layer includes: A second molding die assembly is provided, the second molding die assembly including the main body portion, the protrusion portion and the sealing member; Along the stacking direction of the wind turbine blades, a portion of the blade root layer structure is laid on the second molding die assembly; Along the stacking direction, a blade root flange structure with at least some pre-embedded bolts is installed on a portion of the blade root layer structure, such that the blade root flange structure is installed on one side of the second forming mold assembly along the axial direction, along the axial direction, a portion of the blade root flange structure is opposite to the functional surface, and the peripheral side of the blade root flange structure abuts against the side of the seal facing away from the protrusion. The remaining layer structure of the leaf roots and the remaining pre-embedded bolts are laid to form the leaf root layer structure; The leaf root layer structure is vacuum-infused with matrix material and then cured to obtain a leaf root preform.

9. The wind turbine blade forming method according to claim 8, characterized in that, Before vacuum-infusing the matrix material into the leaf root layer structure, the process further includes: A sealing film is circumferentially covered on the seal.

10. The wind turbine blade forming method according to claim 6, characterized in that, The step of forming the shell structure of the wind turbine blade on the first molding die assembly includes: An outer skin layer is laid on the first molding die assembly; Along the stacking direction of the wind turbine blades, a portion of the blade root layer structure is laid on the first forming mold assembly; Along the stacking direction, a blade root flange structure with at least some pre-embedded bolts is installed on a portion of the blade root layer structure, such that the blade root flange structure is installed on one side of the first forming mold assembly along the axial direction, along the axial direction, a portion of the blade root flange structure is opposite to the functional surface, and the peripheral side of the blade root flange structure abuts against the side of the seal facing away from the protrusion. The remaining layer structure for laying wind turbine blades includes at least the remaining layer structure at the blade root, the main beam, the core material and the blade tip layer structure, and the inner skin layer.

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