Dividing comb for avoiding misalignment of pultruded parts in spar caps

Abstract

The invention relates to a method for manufacturing a reinforcement structure for a wind turbine blade (10), the method comprising the steps of: 1) arranging a plurality of strips (63) of fibrous reinforcement material into adjacent stacks (65a, b, c) of strips forming a layered structure (61) having a plurality of fibrous reinforcement layers (67) wherein adjacent ones of the plurality of fibrous reinforcement layers are separated by an intermediate layer (66), according to the invention, at least one separator comb (70) is provided for the resin (1, 2), the at least one separator comb comprising: a base region (71) and a tooth region (73) comprising a plurality of teeth (74) extending from the base region (71), where the plurality of teeth (74) are arranged with a linear array of gaps (79) between adjacent teeth (74), the gaps (79) being configured for allowing the resin to flow from one side of the separator comb (70) to the other side of the separator comb (70), and wherein the plurality of teeth (74) are configured for penetrating the intermediate layer (66), 3) inserting the at least one separating comb (70) between two adjacent stacks (65a, b, c) of strips and penetrating the plurality of intermediate layers (66) with the plurality of teeth (74) such that a plurality of strips (63) of the adjacent stacks (65a, b, c) of strips are separated by the at least one separating comb (70), 4) after inserting the at least one separating comb (70) between the adjacent stacks (65a, b, c) of strips, the method includes (1) optionally moving the layered structure (61) into a desired position, such as into a wind turbine blade shell mold, (5) optionally removing the at least one divider comb (70), and (6) infusing the layered structure with a resin to form a reinforcing structure (78).

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a partitioning comb for a reinforcing structure of a wind turbine blade, a reinforcing structure, a wind turbine blade and a method of manufacturing thereof. BACKGROUND

[0002] Wind power generation provides a clean and environmentally friendly source of energy. A wind turbine generally includes a tower, a generator, a gearbox, a nacelle, and one or more rotor blades. Wind turbine blades capture the kinetic energy of the wind using known airfoil principles. Modern wind turbines can have rotor blades that exceed 90 meters in length.

[0003] Wind turbine blades are typically manufactured by forming two shell portions or shell halves from layers of woven fabric or fibers and resin. Spar caps or main laminates are placed or integrated in the shell halves and can be combined with shear webs or spar-beams to form structural support members. The spar caps or main laminates can be joined to or integrated within the interior of the suction and pressure halves of the shell.

[0004] As the size of wind turbine blades increases, various challenges arise due to the increased forces such blades are subjected to during operation, requiring improved reinforcing structures. In some known solutions, fiber strip materials are used that are pultruded. Pultrusion is a continuous process in which fibers are pulled through a supply of liquid resin and then heated in an open chamber where the resin is cured. Such pultruded strips can be cut to any desired length.

[0005] WO 2006 / 082479 Al discloses a method for preparing a wind turbine blade shell member comprising a plurality of elements of cured fiber-reinforced sheet material. A plurality of elements of cured fiber-reinforced sheet material are provided in a mold, resin is introduced between the elements of cured fiber-reinforced sheet material, and the elements are bonded to adjacent elements by curing the resin.

[0006] However, manufacturing large reinforcing structures such as spar caps or spar-beams in this way can be challenging, particularly when pultruded carbon fiber reinforced spar caps are used as reinforcing members. Carbon fibers are typically lighter by volume than glass fibers and have improved tensile and compressive strength. In some known methods, individual pultruded elements are used to form the reinforcing structure, and each element is positioned individually within the structure of the shell. This can easily lead to lamination defects such as voids, wrinkles, or misaligned fibers that can have an adverse effect on mechanical properties. In other methods, the pultruded elements are laid outside the shell and subsequently moved into the shell. This process often leads to slight overlaps and / or misalignments of the pultruded layers, which can also have an adverse effect on mechanical properties. SUMMARY

[0007] It is an object of the present invention to provide a reinforcement structure for a wind turbine blade which is easy to manufacture, handle and assemble. It is a further object of the present invention to provide a reinforcement structure for a wind turbine blade which avoids or reduces the misalignments, overlaps and defects discussed above. It is a further object of the present invention to provide a reinforcement structure for a wind turbine blade which has a simple configuration and is relatively inexpensive to manufacture. It is a further object of the present invention to provide an improved method of manufacturing a reinforcement structure for a wind turbine blade.

[0008] It has been found that one or more of the aforementioned objects can be achieved by a method for manufacturing a reinforcement structure for a wind turbine blade, the method comprising the steps of: arranging a plurality of strips of fibre-reinforced material into adjacent stacks of strips forming a layered structure having a plurality of fibre-reinforced layers, wherein adjacent fibre-reinforced layers of the plurality of fibre-reinforced layers are separated by an intermediate layer, providing at least one separating comb comprising: - a base region, - a tooth region comprising a plurality of teeth extending from the base region, - wherein the plurality of teeth are arranged in a linear array having a gap between adjacent teeth, the gap being configured for allowing resin to flow from one side of the separating comb to the other side of the separating comb, and wherein the plurality of teeth are configured for penetrating the intermediate layer, inserting the at least one separating comb between two adjacent stacks of strips and penetrating the plurality of intermediate layers with the plurality of teeth such that the plurality of strips in the adjacent stacks of strips are separated by the at least one separating comb, optionally moving the layered structure to a desired position, such as into a wind turbine blade shell mould, after inserting the at least one separating comb between the adjacent stacks of strips, optionally removing the at least one separating comb, and infusing the layered structure with resin to form the reinforcement structure.

[0009] It has been found that the insertion of at least one separating comb between the stacks of strips in the layered structure prior to resin infusion greatly reduces the undesired overlapping and / or misalignment of the plurality of strips in the layered structure. Importantly, the plurality of teeth of the at least one separating comb is configured for penetrating the intermediate layers of the layered structure. The intermediate layers are resin flow promoting intermediate layers configured for facilitating resin flow between the strips of the fibrous reinforcement material. The teeth can for example be sharp or pointed such that they can punch through the intermediate layers in the layered structure, which allows the separating comb to be easily inserted into the assembled layered structure. The gaps of the separating comb allow for improved resin distribution between adjacent stacks, for example in a VARTM process, while maintaining the desired structural stability. Thus, the separating comb of the present invention facilitates maintaining the required tolerances and positions of the strips along the length of the stacks in the layered structure prior to resin infusion, thereby providing an improved reinforcement structure in which misalignments and defects that can affect the mechanical performance of a wind turbine blade can be avoided.

[0010] A wind turbine blade is typically manufactured from two shell halves (a pressure side shell half and a suction side shell half). The wind turbine blade extends in a spanwise direction between a tip end and a root end of the wind turbine blade corresponding to the length of the wind turbine blade. The wind turbine blade also extends in a chordwise direction between a leading edge and a trailing edge of the wind turbine blade corresponding to the width of the wind turbine blade. The wind turbine blade also extends in a flapwise direction between the two shell halves of the wind turbine blade corresponding to the thickness of the wind turbine blade.

[0011] Preferably, the two shell halves comprise an elongated reinforcement structure, such as a spar cap or a main laminate.

[0012] In preferred embodiments, the reinforcement structure of the present invention is a spar cap or a main laminate for a wind turbine blade. In some embodiments, the reinforcement structure comprises a box spar. In other embodiments, the reinforcement structure comprises a spar beam. The reinforcement structure comprises a resin infused layered structure. Thus, references to the reinforcement structure and the layered structure are sometimes used interchangeably herein. The layered structure comprises a plurality of strips of fibrous reinforcement material arranged in adjacent stacks of strips. The layered structure comprises a plurality of fibrous reinforcement layers, wherein adjacent fibrous reinforcement layers of the plurality of fibrous reinforcement layers are separated by an intermediate layer. Each fibrous reinforcement layer comprises a strip from each of the adjacent stacks of strips. Preferably, each intermediate layer extends between the stacks of strips.

[0013] Preferably, the reinforcement structure extends along the wind turbine blade in the spanwise direction. Typically, the reinforcement structure will extend over 60-95% of the blade length. Thus, the plurality of strips will typically extend in the spanwise direction of the blade, and at least some of the strips preferably have a length corresponding to 60-95% of the blade length.

[0014] In some embodiments, the plurality of strips are pultruded slabs, also known as pultrusions, comprising fibre-reinforced carbon fibre and / or glass fibre.

[0015] Each of the plurality of strips has a length, a thickness, and a height, wherein the length is greater than the thickness and the thickness is greater than the height.

[0016] It is particularly preferred that each strip comprises a pultruded fibre material, such as a pultruded carbon fibre material. In some embodiments, the reinforcing material is carbon fibre and / or glass fibre. In some embodiments, each strip comprises a carbon fibre material. In other embodiments, each strip comprises a glass fibre material. In other embodiments, each strip comprises a glass fibre material and a carbon fibre material. In some embodiments, the strips can not comprise any polymer when laid up. In such embodiments, a polymer resin is typically infused into the strips after laying up.

[0017] Each stack of strips preferably comprises between 2 and 30 strips, such as between 3 and 20 strips, arranged continuously on top of each other in the flapwise direction of the wind turbine blade.

[0018] Each stack will also typically extend in the spanwise direction within the blade. In the middle section between the root end and the tip end, each stack can comprise 8-15 layers of strips, while towards the root end and towards the tip end, the number of layered strips can be reduced to 1-3 layers. Thus, the stacks of strips are preferably tapered both towards the root end and the distal end. Such a configuration advantageously allows a profile that is in line with the thickness profile of the shell. Typically, two or more or three or more stacks of strips are arranged adjacent to each other in the substantially chordwise direction.

[0019] In some embodiments, the plurality of intermediate layers are resin flow promoting layers, such as resin flow promoting fabrics or mats. The intermediate layers are configured for facilitating resin flow between the strips of fibre-reinforced material. In some embodiments, the step of infusing resin into the layered structure comprises enabling resin flow through one or more of the intermediate layers from at least one of the stacks of strips to an adjacent stack of strips through the gaps between adjacent ones of the plurality of teeth. In some embodiments, the plurality of intermediate layers comprises polymer fibre and / or glass fibre and / or carbon fibre. In some embodiments, the intermediate layers are interleaved between the strips of each stack.

[0020] The distinction between the strips of fibre-reinforced material and the intermediate layers is that the strips comprise cured resin, while the intermediate layers do not. Thus, resin can flow through the intermediate layers, while resin cannot flow through the strips.

[0021] The space between adjacent stacks in the layered structure / reinforcement structure is preferably between 0.1 mm and 5.0 mm, such as between 0.5 mm and 1.0 mm, as seen in the substantially chordal direction. The space between adjacent stacks is preferably less than 0.5 mm, or less than 0.3 mm, as seen in the substantially chordal direction. The layered structure / reinforcement structure has a length, a thickness, and a height, wherein the length is greater than the thickness and the thickness is typically greater than the height. The length of the layered structure / reinforcement structure is defined by the length of the strips, the height of the layered structure / reinforcement structure is defined by the height of the stacks of strips including the intermediate layers arranged between the strips, and the thickness of the layered structure / reinforcement structure is defined by the combined thickness of the adjacent stacks of all strips including the space between adjacent stacks.

[0022] In some embodiments, the length of the layered structure / reinforcement structure is in the range of 1 m to 100 m, such as in the range of 1 m to 10 m. In some embodiments, the height of the layered structure / reinforcement structure is in the range of 5 cm to 100 cm, preferably in the range of 5 cm to 50 cm. In some embodiments, the thickness of the layered structure / reinforcement structure is in the range of 10 cm to 300 cm.

[0023] In some embodiments, the layered structure is assembled in the wind turbine blade shell mould. In such embodiments, the partition comb is inserted into the layered structure during or after assembly of the layered structure. In other embodiments, the layered structure is assembled offline, i.e. outside the wind turbine blade shell mould, and subsequently moved to the wind turbine blade shell mould. In such embodiments, the partition comb can be inserted into the layered structure before or after moving the layered structure to the wind turbine blade shell mould. Preferably, the partition comb is inserted before moving of the layered structure to avoid misalignment of the strips during moving. The layered structure is typically infused with resin in the wind turbine blade shell mould. However, in some embodiments, the layered structure can also be infused with resin outside the wind turbine blade shell mould and subsequently moved to the wind turbine blade shell mould.

[0024] Preferably, at least one partition comb is inserted vertically into the layered structure from the top after the plurality of strips are arranged into adjacent stacks, i.e. after assembly of the layered structure, but before resin infusion. The resin infusion can be done, for example, using vacuum assisted resin transfer moulding. In other embodiments, prepreg material can be used for the strips, which comprises a fibre material pre-impregnated with a resin system, such as an epoxy resin. The partition comb can be arranged in certain areas along the layered structure, or arranged at a set distance.

[0025] In some embodiments, the at least one partition comb is removed prior to resin infusion, such that they are not part of the reinforcing structure (i.e. the layered structure after resin infusion). However, the at least one partition comb can also remain in the reinforcing structure, such that they form an integral part of the reinforcing structure and the wind turbine blade.

[0026] Thus, in some embodiments, the at least one partition comb is configured to be removably arranged in the layered structure.

[0027] If the partition comb is removed prior to the infusion step, the partition comb can be made of any suitable material, including a fibre-reinforced material and / or one or more metals and / or one or more polymeric materials, such as a metal sheet, an extruded metal, an extruded or pultruded composite material, or a mixture thereof. In some embodiments, the partition comb is made of a polymeric material, such as a thermoplastic material. In some embodiments, the partition comb comprises or consists of a metal, such as steel. In some embodiments, the partition comb comprises or consists of a glass fibre fabric. In other embodiments, the partition comb comprises or consists of a carbon fibre fabric. In other embodiments, the partition comb comprises or consists of a carbon fibre fabric and a glass fibre fabric.

[0028] In other embodiments, the one or more partition combs are configured to be permanently arranged in the reinforcing structure. If the at least one partition comb is co-infused with the layered structure, it is preferred that the partition comb uses the same material as the plurality of strips, in order to avoid stresses due to mismatch in the coefficient of thermal expansion. In such embodiments, the at least one partition comb is preferably made of an extruded or pultruded composite material. Preferably, the at least one partition comb essentially consists of fibre-reinforced carbon fibres and / or glass fibres. This is because most reinforcing structures and wind turbine blades also essentially consist of carbon fibres and / or glass fibres. Thus, by having the same material in the reinforcing structure and the partition comb, the structural properties of the wind turbine blade and the reinforcing structure are not negatively affected by the presence of the partition comb. However, the at least one partition comb can also be made of a metal sheet, an extruded metal, a polymeric material, and mixtures thereof, as described above for the partition comb configured to be removably arranged in the reinforcing structure.

[0029] The at least one partition comb can be manufactured using an extrusion process, or a pre-designed mould, or 3D printing / additive manufacturing.

[0030] The at least one partition comb has a length, a thickness, and a height, wherein the length and the height are greater than the thickness. The height of the at least one partition comb is equal to the height of the tooth region plus the height of the base region. The length of the at least one partition comb is equal to the length of the tooth region and / or the length of the base region.

[0031] In a preferred embodiment, at least one separator comb has a length ranging from 5 cm to 100 cm, preferably from 5 cm to 50 cm. In some embodiments, at least one separator comb has a height ranging from 5 cm to 100 cm, such as from 5 cm to 50 cm, preferably from 10 cm to 30 cm. In some embodiments, at least one separator comb has a thickness ranging from 0.1 mm to 10 mm, preferably from 0.5 mm to 5 mm (such as 1 mm).

[0032] The precise dimensions of at least one separator comb depend on the dimensions of the layered structure in which the separator comb will be arranged. Therefore, the dimensions of the separator comb are predetermined based on the dimensions of the layered structure in which the separator comb will be arranged.

[0033] Preferably, one or more separator combs are vertically inserted between two adjacent stacks of the strip, and multiple intermediate layers are penetrated by multiple teeth, such that multiple strips in adjacent stacks of the strip are separated by at least one separator comb along the entire height of the layered structure. In this way, overlap of strips in adjacent stacks is avoided. Vertical insertion means that at least one separator comb is inserted into the layered structure at an angle perpendicular to or substantially perpendicular to the multiple fiber reinforcement layers.

[0034] The thickness of at least one separator comb depends on the desired separation between adjacent stacks of strips in the layered structure. Therefore, the thickness of at least one separator comb is configured to correspond to a predetermined spacing between two adjacent stacks in the layered / reinforced structure. When arranged between adjacent stacks in a wind turbine blade shell component, this distance typically extends in a substantially chordal direction.

[0035] At least one separator comb is preferably much shorter than the length of the layered / reinforcing structure. This is because it is unnecessary to separate the stacks of strips along their entire length to avoid overlap or misalignment. Additionally, shorter separator combs are easier to insert into the layered / reinforcing structure, easier to transport, and cheaper to manufacture. Instead of having a single long separator comb, one or more (such as one, two, or three) smaller separator combs can be arranged between two adjacent stacks to avoid overlap and misalignment between strips in adjacent stacks along their entire length.

[0036] The height of at least one separator comb is defined between the edge of the basal region of the teeth and the tip of the tooth furthest from the tooth tip. The preferred height of the at least one separator comb depends on the height of the layered / reinforcing structure.

[0037] In a preferred embodiment, the height of at least one separator comb is configured to be the same as or substantially the same as the height of the stack (including multiple intermediate layers) of the layered / reinforcing structure into which the separator comb is configured to be inserted. Therefore, preferably, the separator comb has a height equal to the height of the layered structure, such that when at least one separator comb is inserted between two adjacent stacks of a strip and penetrates multiple intermediate layers with multiple teeth, multiple strips in adjacent stacks of the strip are separated by at least one separator comb along the entire height of the layered structure. In this way, the separator comb can efficiently separate two stacks of strips in the reinforcing structure without pulling them from the reinforcing structure. Preferably, when inserted between adjacent stacks in the reinforcing structure, the separator comb should be flush with or substantially flush with the upper surface of the reinforcing structure. This is especially important if the separator comb will be permanently inserted into the reinforcing structure. In this way, the separator comb will not have any negative impact on the mechanical properties of the reinforcing structure.

[0038] However, in some embodiments, the separator comb has a height greater than the height of the layered structure, such that when at least one separator comb is inserted between two adjacent stacks of a strip and penetrates multiple intermediate layers with multiple teeth, multiple strips in adjacent stacks of the strip are separated by at least one separator comb along the entire height of the layered structure, and the separator comb protrudes from the layered structure. This is advantageous if the separator comb is to be removed from the layered structure before resin infusion, because the protruding portion of the separator comb will allow the separator comb to be easily identified and removed, for example, by grasping the protruding portion of the separator comb. Alternatively, the separator comb may include a shank or another protruding element that is attached to the base region of the separator comb on a surface opposite to the multiple teeth, configured to protrude from the upper surface of the layered structure to allow the separator comb to be easily removed from the layered structure.

[0039] In a less preferred embodiment, the separator comb has a height less than that of the layered / reinforcing structure. In such embodiments, the height of the base region is reduced, rather than the height of the tooth region and / or multiple teeth. This is because it is not preferred for the base region of at least one separator comb to cover the interface where resin can flow between the two stacks of the strip, i.e., through the intermediate layer.

[0040] Therefore, in a preferred embodiment, the tooth region of at least one separator comb has a height equal to the height of the layered structure minus the height of the uppermost fiber reinforcement layer among the plurality of fiber reinforcement layers. If it is desired that the separator comb be flush with the upper surface of the layered structure, then the base region of at least one separator comb has a height equal to the height of the uppermost fiber reinforcement layer of the layered structure. If it is desired that the separator comb protrude from the upper surface of the layered structure, then the base region of at least one separator comb has a height greater than the height of the uppermost fiber reinforcement layer of the layered structure.

[0041] However, in some embodiments, the tooth region of at least one separator comb has a height greater than the height of the layered structure minus the height of the uppermost fiber reinforcement layer, and / or in some embodiments, the base region of at least one separator comb has a height less than the height of the uppermost fiber reinforcement layer of the layered structure.

[0042] In some embodiments, the base region is substantially rectangular.

[0043] In some embodiments, the base region has a thickness corresponding to a predetermined spacing between two adjacent stacks in the reinforcing structure. In some embodiments, the thickness of the base region is constant or substantially constant. In some embodiments, the thickness of the base region is in the range of 0.1 mm to 1 mm, preferably in the range of 0.5 mm to 5 mm, such as about 1 mm.

[0044] In some embodiments, the plurality of teeth includes between 2 and 100 teeth, such as between 2 and 50 teeth, preferably between 5 and 10 teeth.

[0045] In some embodiments, all the teeth in the plurality of teeth extend substantially in parallel.

[0046] The height of the plurality of teeth is defined between the tips of the teeth and the edges of the basal regions closest to the tips of the teeth. In some embodiments, all teeth in the plurality of teeth have substantially the same height.

[0047] In some embodiments, all teeth in the plurality of teeth have substantially the same length and thickness.

[0048] In some embodiments, the multiple teeth are identical or substantially identical in shape and size.

[0049] In some embodiments, the teeth have pointed or sharp tips. This facilitates penetration of the intermediate layer.

[0050] In some embodiments, the length and / or thickness of the plurality of teeth decreases from the base to the tip. In some embodiments, all teeth in the plurality of teeth have sharp or pointed edges along their height. This decreasing length and / or thickness of the plurality of teeth from the base to the tip is particularly advantageous for penetration of the intermediate layer.

[0051] In some embodiments, the thickness of the plurality of teeth is substantially constant along the height of the teeth.

[0052] In some embodiments, the length of the plurality of teeth is in the range of 0.1 mm to 10 mm, such as between 0.5 mm and 5 mm, such as 1 mm. In some embodiments, the thickness of the plurality of teeth is in the range of 0.1 mm to 10 mm, such as between 0.5 mm and 5 mm, such as 1 mm.

[0053] In some embodiments, the maximum thickness of the plurality of teeth is the same as the thickness of the base region.

[0054] In some embodiments, the plurality of teeth have a circular or elliptical cross-section along their height. In such embodiments, the diameter of the plurality of teeth is in the range of 0.1 mm to 10 mm, such as between 0.5 mm and 5 mm, such as 1 mm. In some embodiments, the diameter of the plurality of teeth decreases from the base to the tip. In some embodiments, the maximum diameter of the plurality of teeth is the same as the thickness of the base region. In some embodiments, the diameter at the tip of the plurality of teeth is between 0.5 mm and 5 mm, such as 1 mm.

[0055] In a preferred embodiment, each of the separator combs includes a plurality of gaps to allow resin to flow from one side of the separator comb to the other. The gaps are defined between two adjacent teeth in the tooth region of the separator comb. Each separator comb may include between 2 and 100 gaps, preferably between 10 and 50 gaps. Even when at least one separator comb is present in the reinforcing structure, the gaps allow resin to migrate from one stack of strips to another stack of strips. The gaps may be slits, grooves, or channels, such as longitudinally extending grooves.

[0056] In some embodiments, the gap between the tips of adjacent teeth in the plurality of teeth is between 3 mm and 200 mm, preferably between 3 mm and 50 mm, more preferably between 3 mm and 10 mm, such as 5 mm. The gap should be at least 3 mm, such as at least 4 mm, such as at least 5 mm, to allow resin to flow from one stack of strips to another stack of strips. If the gap is too narrow, the resin flow will be interfered with by the separator comb, which may result in uneven resin distribution in the area where the separator comb is inserted. This is undesirable.

[0057] In a preferred embodiment, when the separator comb is arranged in a layered structure, the gaps are positioned as interfaces between two adjacent strips within a stack of strips. In a preferred embodiment, at least one, preferably several or all, of the gaps are positioned adjacent to an intermediate layer arranged between adjacent strips. This has been found to enable a particularly advantageous resin distribution process within and across stacks of strips.

[0058] In another aspect, the present invention relates to a reinforcement structure for wind turbine blades, the reinforcement structure comprising: a plurality of strips of fiber-reinforced material arranged in an adjacent stack to form a layered structure having a plurality of fiber-reinforced layers. Multiple intermediate layers are arranged between multiple fiber reinforcement layers, such that adjacent fiber reinforcement layers are separated by intermediate layers. At least one dividing comb is arranged between adjacent stacks of strips. At least one of the separator combs includes: - Base region, - The tooth region, which includes multiple teeth extending from the base region. - In this configuration, multiple teeth are arranged in a linear array with gaps between adjacent teeth, the gaps being configured to allow resin to flow from one side of the separator comb to the other side. - In this process, multiple teeth penetrate multiple intermediate layers.

[0059] In a preferred embodiment, a plurality of strips, a plurality of intermediate layers, and at least one spacer comb are embedded in the cured resin. In some embodiments, the resin is an epoxy resin or a vinyl ester resin.

[0060] In some embodiments, multiple separator combs (such as two, three, four, five, six, or even more than six separator combs) are arranged between adjacent stacks of strips in the reinforcing structure. If there are more than two adjacent stacks of strips, such as three adjacent stacks of a strip including a first, second, and third stack, the reinforcing structure preferably includes at least two separator combs, one for separating the first and second stacks, and one for separating the second and third stacks. In some embodiments, the reinforcing structure includes two separator combs for each number of adjacent stacks of the strip. For example, if the reinforcing structure includes three adjacent stacks of the strip, including a first stack, a second stack, and a third stack, the reinforcing structure preferably includes at least four separator combs, two for separating the first and second stacks, and two for separating the second and third stacks.

[0061] In another aspect, the present invention relates to a method for manufacturing a reinforcing structure for wind turbine blades, the method comprising the following steps: Multiple strips of fiber-reinforced material are arranged in adjacent stacks to form a layered structure with multiple fiber-reinforced layers, wherein adjacent fiber-reinforced layers are separated by an intermediate layer. At least one separating structure is provided, the at least one separating structure including one or more teeth configured to penetrate the intermediate layer, such as multiple teeth. One or more teeth are inserted between two adjacent stacks of strips, and one or more teeth penetrate multiple intermediate layers, such that multiple strips in adjacent stacks of strips are separated by one or more teeth. After inserting one or more toothed inserts between adjacent stacks, the layered structure can optionally be moved to a desired location, such as into a wind turbine blade shell mold. Optionally, one or more teeth can be removed, and Layered structures are infused with resin to form a reinforcing structure.

[0062] In another aspect, the present invention relates to a reinforcement structure for wind turbine blades, the reinforcement structure comprising a plurality of strips of fiber-reinforced material arranged in an adjacent stack to form a layered structure having a plurality of fiber-reinforced layers. Multiple intermediate layers are arranged between multiple fiber reinforcement layers, such that adjacent fiber reinforcement layers are separated by intermediate layers. At least one dividing structure is arranged between adjacent stacks of strips. In this embodiment, at least one separating structure includes one or more teeth, such as multiple teeth, wherein each of the multiple teeth separates two adjacent stacks of the strip and penetrates multiple intermediate layers.

[0063] All the relevant features and embodiments discussed above regarding the method of manufacturing a reinforcing structure including a separator comb and the reinforcing structure including a separator comb are equally applicable to the method of manufacturing a reinforcing structure including a separator comb comprising one or more teeth and the reinforcing structure including a separator comb comprising one or more teeth. Although a separator comb is preferred as the separator structure, one or more teeth can adequately separate adjacent stacks of strips due to the stability and ease of handling provided by the base region.

[0064] In another aspect, the present invention relates to a wind turbine blade comprising a reinforcing structure having at least one septum comb or septum structure as described herein.

[0065] In some embodiments, the wind turbine blade has a shaped profile including a pressure side and a suction side, as well as a leading edge and a trailing edge, wherein a chord having a chord length extends between the leading edge and the trailing edge, and the wind turbine blade extends in the spanwise direction between a root tip and a tip tip.

[0066] In another aspect, the present invention relates to a method for manufacturing a wind turbine blade including a reinforced structure, the wind turbine having a shaped profile including a pressure side and a suction side, and a leading edge and a trailing edge, wherein a chord having a chord length extends between the leading edge and the trailing edge, and the wind turbine blade extends in the spanwise direction between a root tip and a tip tip, the method comprising the following steps: Provide blade shell molds, Multiple blade shell assemblies are arranged in a blade shell mold. Assemble the layered structure in a blade shell mold or assemble the layered structure at a location different from the blade shell mold and then move the layered structure to the blade shell mold, wherein the assembly of the layered structure includes: Multiple strips of fiber-reinforced material are arranged in adjacent stacks to form a layered structure with multiple fiber-reinforced layers, wherein adjacent fiber-reinforced layers are separated by an intermediate layer. Provide at least one separator comb, the separator comb comprising: - Base region, - The tooth region, which includes multiple teeth extending from the base region. - Wherein, multiple teeth are arranged in a linear array with gaps between adjacent teeth, the gaps being configured to allow resin to flow from one side of the separator comb to the other side, and wherein the multiple teeth are configured to penetrate the intermediate layer. At least one separator comb is inserted between two adjacent stacks of the strip and penetrates multiple intermediate layers with multiple teeth, such that multiple strips in adjacent stacks of the strip are separated by at least one separator comb along the entire height of the layered structure. Optionally, at least one separator comb can be removed, and Resin is infused into a blade shell mold to form a resin-infused reinforcing structure within the wind turbine blade shell, and Two wind turbine blade shells are combined to form a wind turbine blade.

[0067] In another aspect, the present invention relates to wind turbine blades comprising an enhancement structure as described herein, the enhancement structure including at least one septum comb.

[0068] In some embodiments, the step of infusing resin into the stack of strips includes achieving resin flow from at least one stack of strips to adjacent stacks of strips through gaps between adjacent teeth of a plurality of teeth. Such resin flow typically occurs within the blade mold in a substantially tangential direction. In some embodiments, resin may be infused into the stack closest to the leading edge or the trailing edge of the blade, wherein resin flow is achieved through gaps from that stack of the reinforcing structure to other stacks (e.g., tangentially toward the trailing edge or toward the leading edge). In other embodiments, in the tangential direction, resin may be infused into the stack located at the center of the reinforcing structure, wherein resin flow is achieved through gaps from that stack of the reinforcing structure to other stacks (i.e., toward the leading edge and toward the trailing edge).

[0069] In a preferred embodiment, the pressure-side shell half and the suction-side shell half of the blade are preferably manufactured in corresponding mold halves by vacuum-assisted resin transfer molding. According to some embodiments, each of the pressure-side shell half and the suction-side shell half has a longitudinal range of 50-150 m, preferably 60-80 m. In a preferred embodiment, each of the pressure-side shell half and the suction-side shell half comprises one or more layers of carbon fiber.

[0070] According to some embodiments, the method further includes arranging one or more shear webs in at least one of the shell halves, typically at the location of a reinforcing structure. Each shear web may include a web body, a first web foot flange at a first end of the web body, and a second web foot flange at a second end of the web body. In some embodiments, the shear web is substantially I-shaped. Alternatively, the shear web may be substantially C-shaped.

[0071] In another aspect, the present invention relates to a separator comb configured to separate adjacent stacks of strips having multiple fiber-reinforced layers forming a spar cap for a wind turbine blade, wherein adjacent fiber-reinforced layers are separated by an intermediate layer. The separator comb includes: - Base region, - A toothed region comprising a plurality of teeth extending from the base region, wherein the toothed region has a height equal to or greater than the height of the spar cap minus the height of the uppermost fiber reinforcement layer among the plurality of fiber reinforcement layers. - In this configuration, multiple teeth are arranged in a linear array with gaps between adjacent teeth, the gaps being configured to allow resin to flow from one side of the separator comb to the other side. - Among them, multiple teeth are configured to penetrate the intermediate layer.

[0072] In another aspect, the present invention relates to a partition structure comprising at least two partition combs as described herein, wherein the at least two partition combs are connected by connecting elements.

[0073] In some embodiments, the connecting element is a plate and is connected to the base region of at least two separator combs, such that when the separator combs are inserted between adjacent stacks of strips, the connecting element is configured to be arranged on top of the layered structure.

[0074] In some embodiments, the connecting element includes a handle or protruding element that allows easy removal of the separating structure from the layered structure.

[0075] In some embodiments, the partition structure is substantially rack-shaped.

[0076] In some embodiments, the connecting elements of the partition structure extend throughout the spanwise and / or chordwise range of the layered structure in the wind turbine blade.

[0077] According to another aspect, the present invention relates to a component for a wind turbine blade, the component comprising a separator comb and a plurality of stacked fiber reinforcement layers, wherein the separator comb includes a base region and a tooth region, the tooth region including a plurality of teeth extending from the base region, and wherein the plurality of teeth of the tooth region of the separator comb penetrate the plurality of stacked fiber reinforcement layers.

[0078] In a preferred embodiment, a plurality of teeth are arranged in a linear array with gaps between adjacent teeth, the gaps being configured to allow resin to flow from one side of the separator comb to the other side.

[0079] According to another preferred embodiment, the plurality of stacked fiber reinforcement layers comprise adjacent stacks of fiber reinforcement layers forming a spar cap for a wind turbine blade, wherein the fiber reinforcement layers within each stack are separated by an intermediate layer, and wherein the toothed region has a height equal to or greater than the height of the spar cap minus the height of the uppermost fiber reinforcement layer among the plurality of stacked fiber reinforcement layers. In an advantageous embodiment, the plurality of teeth are configured to penetrate the intermediate layer.

[0080] According to another preferred embodiment, the component includes at least two separator combs according to any one of the preceding claims, wherein the at least two separator combs are connected by a connecting element.

[0081] According to yet another aspect, the present invention relates to a wind turbine blade that can be obtained by the method described herein. The above-described embodiments and features of the method for manufacturing the reinforcing structure are equally applicable to other aspects of the invention, including those related to the partition comb, partition structure, reinforcing structure, wind turbine blade, and method for manufacturing the wind turbine blade, and vice versa. Attached Figure Description

[0082] Embodiments of this disclosure will now be described in more detail with reference to the accompanying drawings. The drawings illustrate one mode of implementing this disclosure and should not be construed as limiting other possible embodiments falling within the scope of the appended claims.

[0083] Figure 1 It is a schematic diagram of a wind turbine. Figure 2 It is a schematic illustration of a three-dimensional and cross-sectional view of a wind turbine blade. Figure 3 These are schematic illustrations of a top view and a cross-sectional view of a reinforcement structure in a wind turbine blade, according to the prior art, which illustrates the misalignment of strips in the reinforcement structure. Figure 4 These are schematic illustrations of the front view of the separator comb according to different embodiments of the present invention. Figure 5 This is a schematic illustration of a three-dimensional view of the dimensions of the dividing comb relative to the reinforcing structure in the form of a spar cap, according to an embodiment of the present invention. Figure 6 These are schematic illustrations of cross-sectional views of a reinforcing structure including a separator comb, according to different embodiments of the present invention. as well as Figure 7These are schematic illustrations of a partition structure and a reinforcing structure including the partition structure according to an embodiment of the present invention. Detailed Implementation

[0084] Various exemplary embodiments and details are described below with reference to the accompanying drawings (where applicable). It should be noted that the drawings may be drawn to scale or not, and elements with similar structures or functions are indicated by the same reference numerals throughout the drawings. It should also be noted that the drawings are intended merely to facilitate the description of embodiments. They are not intended as an exhaustive description of the invention or as a limitation on the scope of the invention. Furthermore, the illustrated embodiments do not need to have all the aspects or advantages shown. Aspects or advantages described in connection with a particular embodiment are not necessarily limited to that embodiment and may be practiced in any other embodiment even if not so illustrated or so explicitly described.

[0085] Figure 1 The illustration depicts a conventional modern upwind turbine based on the so-called "Danish concept," featuring a tower 4, a nacelle 6, and a rotor with a substantially horizontal rotor shaft. The rotor comprises a hub 8 and three blades 10 extending radially from the hub 8, each blade having a blade root 16 closest to the hub and a blade tip 14 furthest from the hub 8. The rotor has a radius denoted as R.

[0086] Figure 2 A schematic diagram of a wind turbine blade 10 is shown. The wind turbine blade 10 has the shape of a conventional wind turbine blade and includes a root region 30 closest to the hub, a profiled or airfoil region 34 furthest from the hub, and a transition region 32 between the root region 30 and the airfoil region 34. The blade 10 includes a leading edge 18 facing the direction of rotation of the blade 10 when the blade is mounted on the hub, and a trailing edge 20 facing the opposite direction to the leading edge 18.

[0087] Airfoil region 34 (also called the profile region) has an ideal or near-ideal blade shape in terms of lift generation, while root region 30 has a substantially circular or elliptical cross-section due to structural considerations, which, for example, makes it easier and safer to mount the blade 10 to the hub. The diameter (or chord) of root region 30 may be constant along the entire root region 30. Transition region 32 has a transition profile that gradually changes from the circular or elliptical shape of root region 30 to the airfoil profile of airfoil region 34. The chord length of transition region 32 typically increases with increasing distance r from the hub. Airfoil region 34 has an airfoil profile with a chord extending between the leading edge 18 and trailing edge 20 of blade 10. The width of the chord decreases with increasing distance r from the hub.

[0088] The shoulder 40 of the blade 10 is defined as the location where the blade 10 has its maximum chord length. The shoulder 40 is typically located at the boundary between the transition region 32 and the airfoil region 34. Figure 2 A also illustrates the longitudinal range, length, or longitudinal axis of the blade.

[0089] It should be noted that the chords of different sections of the blade are usually not located in a common plane because the blade may be twisted and / or bent (i.e., pre-bent), thus providing a corresponding twisted and / or bent path to the chord plane is to compensate for the most common case of the local velocity of the blade depending on the radius from the hub.

[0090] The blade is typically made of a pressure-side shell portion 36 and a suction-side shell portion 38, which are glued to each other along a bonding line at the leading edge 18 and trailing edge of the blade 20.

[0091] Figure 2 B shows the blade along Figure 2 A schematic diagram of the cross-section of line II shown in Figure A. As previously mentioned, blade 10 includes a pressure-side shell portion 36 and a suction-side shell portion 38. The pressure-side shell portion 36 includes a sparsor cap 45, also referred to as the primary laminate, which constitutes the load-bearing portion of the pressure-side shell portion 36. The sparsor cap 45 includes multiple fiber layers 42, which primarily consist of unidirectional fibers aligned along the longitudinal direction of the blade to provide stiffness to the blade. The suction-side shell portion 38 also includes a sparsor cap 45, which includes multiple fiber layers 46. The pressure-side shell portion 36 may also include a sandwich core material 43, which is typically made of balsa wood or a foamed polymer and sandwiched between multiple fiber-reinforced skin layers. The sandwich core material 43 is used to provide stiffness to the shell to ensure that the shell substantially maintains its aerodynamic profile during blade rotation. Similarly, the suction-side shell portion 38 may also include a sandwich core material 47.

[0092] The spar caps 45 of the pressure side shell portion 36 and the suction side shell portion 38 are connected via a first shear web 50 and a second shear web 55. In the illustrated embodiment, the shear webs 50 and 55 are shaped as substantially I-beam-shaped webs. The first shear web 50 includes a shear web body and two web foot flanges. The shear web body includes a sandwich core material 51, such as balsa wood or a foamed polymer, covered by a plurality of skin layers 52 made of multiple fiber layers.

[0093] The blade shells 36 and 38 may include additional fiber reinforcement at the leading and trailing edges. Typically, the shell portions 36 and 38 are bonded to each other via glued flanges.

[0094] Figure 3A is a schematic top view of the shell half 38 of a wind turbine blade including a reinforcing structure 62 according to the prior art. The reinforcing structure 62 is in the form of a sparsus cap and is arranged within the shell half 38. In the illustrated embodiment, the reinforcing structure 62 includes three adjacent stacks 65a, 65b, 65c of strips of fiber-reinforcing material arranged adjacent to each other. Figure 3 In A, only the topmost bars 64a, 64b, and 64c of each stack 65a, 65b, and 65c can be seen.

[0095] Figure 3 B is through Figure 3 The cross section aa shown in Figure A Figure 3 A schematic cross-sectional view of the reinforcing structure 62 of A. (See also...) Figure 3 As can be seen in B, each stack 65a, 65b, 65c of the reinforcing structure 62 includes three strips 63a, 64a, 63b, 64b, 63c, 64c. Nine strips 63a, 64a, 63b, 64b, 63c, 64c of the fiber-reinforcing material are arranged in adjacent stacks 65a, 65b, 65c, forming a layered structure 61 with three fiber-reinforcing layers 67, 68, including the uppermost fiber-reinforcing layer 68. Each fiber-reinforcing layer 67, 68 includes strips 63a, 64a, 63b, 64b, 63c, 64c from each of the adjacent stacks 65a, 65b, 65c. Furthermore, Figure 3 The reinforcing structure 62 of B includes two intermediate layers 66 disposed between three fiber reinforcing layers 67, 68, such that adjacent fiber reinforcing layers 67, 68 are separated by the intermediate layers 66.

[0096] Figure 3 C and Figure 3 Diagram D illustrates how strips 63a, 64a, 63b, 64b, 63c, and 64c can move within reinforcing structure 62, resulting in misalignment and overlap of strips 63a, 64a, 63b, 64b, 63c, and 64c. Figure 3 In C, strips 63b and 63c have moved horizontally, while... Figure 3 In D, strips 63b, 64b, 63c, and 64c overlap. (As shown in...) Figure 3 C and Figure 3 As can be seen in D, such misalignment and overlap affect the final shape of the reinforcement structure 62, which is undesirable. This problem is solved by the present invention, which has been found to result in a greatly improved final reinforcement structure 62 with almost no misalignment or associated structural defects in the reinforcement structure 63.

[0097] Figure 4 A to Figure 4C is a schematic front view illustration of different embodiments of the separator comb 70 according to the present invention. The separator comb 70 is configured to form a layered structure by resin infusion to create... Figure 5 and Figure 6 The reinforcing structure 62 of the wind turbine blade 10 shown in the figure is inserted between adjacent stacks 65a, 65b, and 65c of the layered structure strips.

[0098] like Figure 4 A to Figure 4 As can be seen in C, the separator comb 70 of the present invention includes a base region 71 and a tooth region 73. The tooth region 73 includes a plurality of teeth 74 extending from the base region 71 and arranged in a linear array having gaps 79 between adjacent teeth 74. The gaps 79 are configured to allow resin to flow from one side of the separator comb 70 to the other side of the separator comb 70, while the teeth 74 are configured to penetrate the sheet material (such as a plurality of intermediate layers 66 of a layered structure) before resin is infused to form a reinforcing structure 62.

[0099] The separator comb 70 has a length 70l, a thickness 70t, and a height 70h, wherein the length 70l and the height 70h are greater than the thickness 70t. Figure 4 A to Figure 4 Only the length 70l and height 70l of the dividing comb 70 can be seen in C.

[0100] The base region 71 is substantially rectangular and has a length 71l that defines the length 70l of the dividing comb. However, the base region 71 may also have another shape, as long as it is structurally stable and can support multiple teeth 71.

[0101] The height 71h of the base region 71 depends on the height of the uppermost bars 64a, 64b, and 64c of the reinforcing structure 62 in which the dividing comb 70 will be arranged. This will combine Figure 5 A. Further discussion.

[0102] exist Figure 4 In A, the separator comb 70 includes seven teeth 74 and six gaps 79. Figure 4 In section B, the separator comb 70 includes twelve teeth 74 and eleven gaps 79. Figure 4 In C, the separator comb 70 includes eight teeth 74 and seven gaps 79.

[0103] Each of the teeth 74 has a height of 74h, a length of 74l, and a thickness of 74t. Figure 4 A to Figure 4 Only height 75h and length 74l are visible in C. The height 74h of each tooth 74 is defined between the tip 75 of the plurality of teeth 74 and the edge 80 of the base region closest to the tip 75 of the tooth 74.

[0104] likeFigure 4 A to Figure 4 As can be seen in C, the gaps 79 between the multiple teeth 74 and the tooth regions 73 can have many different shapes. The teeth 74 can have sharp or pointed tips 75 to facilitate penetration of the intermediate layer 66. Importantly, the teeth 74 are structurally stable, i.e., not easily broken. Finally, it is important that the gaps 79 are large enough to allow resin to wet all or substantially all of the intermediate layer 66 of the layered structure into which the separator comb 70 is inserted when the layered structure is infused with resin. In cases where the gaps 79 are too narrow at some points between adjacent teeth 74, such as... Figure 4 As seen in B, the gap 79 is very narrow near the base region 71, and may not be large enough to allow resin to flow effectively from one side of the separating comb 70 to the other side of the separating comb 70 in this region.

[0105] exist Figure 4 A to Figure 4 In C, all the teeth 74 of the separator comb 70 extend in parallel and have the same height 74h, length 74l, and thickness 74t. However, it is not necessary for all the teeth 74 to extend in parallel and have the same height 74h, length 74l, and thickness 74t.

[0106] Preferably, the height 73h of the tooth region and the height 74h of the plurality of teeth are equal to or greater than the height 65h of the stacks 65a, 65b, 65c, respectively. For example, the height of the layered structure into which the separator comb 70 is inserted is reduced by the height 64h of the uppermost strips 64a, 64b, 64c of the stacks 65a, 65b, 65c, or by the height 68h of the uppermost fiber reinforcement layer 68. This will combine Figure 5 and Figure 6 Let's discuss this in more detail.

[0107] exist Figure 4 A and Figure 4 In B, all the multiple teeth 74 are substantially identical. This can facilitate a uniform resin distribution throughout the reinforcing structure 62, but it is not necessary for a uniform resin distribution. For example, as... Figure 4 As seen in C, the outermost tooth 74 of the separator comb 70 does not have the same shape as the other teeth 74. In other embodiments, the teeth 74 other than the outermost tooth 74 may have a different shape than the other teeth 74.

[0108] In some embodiments, the plurality of teeth 74 also have sharp or pointed edges along their height 74h. This can facilitate better penetration of the intermediate layer 66 in the reinforcing structure 62, especially if the length of the teeth 74 decreases from the base region 71 toward the tip 75 of the teeth 74.

[0109] exist Figure 4In A, the length 74l of the multiple teeth 74 is constant along the height 74h of the multiple teeth 74. However, in Figure 4 B and Figure 4 In C, the length 74l of the tooth 74 decreases from the base region 71 toward the tip 75 of the tooth 74. Similarly, the thickness 74t of the tooth 74 can be constant along its height 74h, or it can decrease from the base region 71 toward the tip 75. Preferably, the maximum thickness 74t of the plurality of teeth 74 is the same as the thickness 71t of the base region 71. In some embodiments, the plurality of teeth 74 may have a circular or elliptical cross-section.

[0110] Figure 5 A is a schematic perspective view of a dividing comb 70 arranged next to the stack 65 of strips 63 and 64, to illustrate the relative size of the dividing comb 70 to the stack 65 of strips 63 and 64.

[0111] like Figure 5 As can be seen in A, the stack of strips 65 comprises three strips 63 and 64, including the topmost strip 64. Each of the strips 63 and 64 has a length 63l and 64l, a thickness 63t and 64t, and a height 63h and 64h, respectively, wherein the lengths 63l and 64l are greater than the thicknesses 63t and 64t, and the thicknesses 63t and 64t are greater than the heights 63h and 64h. The length 65l and thickness 65t of the stack 65 are the same as the lengths 63l and 64l and the thicknesses 63t and 64t of each strip. However, the height 65h of the stack 65 is the heights 63h and 64h of the three combined strips plus the height of the two intermediate layers 66 arranged between the strips 63 and 64.

[0112] like Figure 5 As can be seen in A, the separator comb 70 includes a base region 71 and a tooth region 73 comprising multiple teeth 74. Regarding Figure 4 A to Figure 4 C describes the characteristics of the separator comb 70 in more detail.

[0113] As in Figure 5 A and in Figure 5 B Figure 6 A and Figure 6 As can be seen in section B, the height 74h of the toothed region 73 and the plurality of teeth 74 is equal to the height 65h of the stack of strips including the intermediate layer minus the height of the uppermost strip 64 of the stack 65. This allows for optimal separation between adjacent stacks 65 of the strips and optimal resin flow through the intermediate layer 66 between adjacent stacks 65. However, the toothed region 73 and the plurality of teeth 74 may also be higher than the stack 65 of the strips minus the height 64h of the uppermost strip. However, it is preferred that it is not lower, as this would impair optimal separation between adjacent stacks or impair resin flow between adjacent stacks.

[0114] As in Figure 5A and in Figure 5 B and Figure 6 As can be seen in A, the height 70h of the separator comb 70 is the same as or substantially the same as the height 65h of the stack 65 of strips 63 and 64 (including the height of the intermediate layer 66). The height 71h of the base region 71 is the same as the height 64h of the uppermost strip 64 of the stack 65 of strips 63 and 64. In this way, when the layered structure 61 is resin-infused to form a reinforcing structure 62 for wind turbine blades, the base region 71 does not obstruct the resin flow through the intermediate layer 66 between adjacent stacks 65 of strips 63 and 64. This can also be achieved if the height 71h of the base region 71 is smaller than that of the uppermost strip 64. However, the base region 71 provides structural stability to the separator comb 70. Therefore, the base region 71 with a smaller height 71h may be more prone to breakage.

[0115] In some embodiments, the height 71h of the base region 71 may also be greater than the height 64h of the uppermost strip 64. However, in such embodiments, the base region 71 will protrude from the layered structure 61 upon insertion, as... Figure 6 As shown in Figure C.

[0116] The maximum thickness 70t of the separator comb is configured to correspond to a predetermined spacing between two adjacent stacks 65 in the layered structure 61. The thickness 70t of the separator comb 70 can be constant or variable. Figure 5 A, Figure 5 B Figure 6 A and Figure 6 In B, the thickness 70t of the separator comb 70 is constant.

[0117] Figure 5 B is a schematic perspective view of a layered structure 61 in the form of a spar cap before resin infusion, wherein two separator combs 70 are positioned between adjacent stacks 65a, 65b, 65c of the insert strip.

[0118] As in Figure 5 As can be seen in B, the layered structure 61 comprises three stacks 65a, 65b, and 65c of strips, wherein each stack 65a, 65b, and 65c comprises three strips 63a, 64a, 63b, 64b, 63c, and 64c. Nine strips 63a, 64a, 63b, 64b, 63c, and 64c are arranged in adjacent stacks 65a, 65b, and 65c to form a layered structure 61 having three fiber reinforcement layers 67 and 68, including an uppermost fiber reinforcement layer 68. Each fiber reinforcement layer 67 and 68 comprises strips 63a, 64a, 63b, 64b, 63c, and 64c from each of the adjacent stacks 65a, 65b, and 65c. Furthermore, the layered structure 61 includes two intermediate layers 66 disposed between the three fiber reinforcement layers 67 and 68.

[0119] Figure 6 A is achieved by inserting two separator combs 70° between adjacent stacks of strips. Figure 5 A cross-sectional view of the layered structure 61 of B. When the layered structure is infused with resin, it is a reinforcing structure 62 constructed as a spar cap for a wind turbine blade. Figure 6 B is a close-up view of two stacked layers 65a and 65b of the layered structure 61, and Figure 6 C is a close-up view of two stacks 65a, 65b of the layered structure 61, which includes a separator comb 70 inserted between adjacent stacks of strips and penetrating the intermediate layer with multiple teeth, such that multiple strips in adjacent stacks of strips are separated by the separator comb 70 along their entire height. The height 70h of the separator comb is greater than the height 61h of the layered structure, and the height 71h of the base region is greater than the height 64h of the uppermost strips 64a, 64b of the stacks of strips 65a, 65b and the height 68h of the uppermost fiber reinforcement layer of the layered structure 61. As can be seen in both embodiments, and as per [reference to...] Figure 5 As described in A, the height 74h of the tooth region 73 and the plurality of teeth 74 is preferably equal to or greater than the height 64h of the uppermost strips 64a, 64b of the stacks 65a, 65b of the layered structure 61 minus the height 68h of the uppermost fiber reinforcement layer of the layered structure 61. This allows for optimal separation of adjacent stacks 65a, 65b and optimal resin flow between adjacent stacks 65a, 65b through the intermediate layer 66. Figure 6 Figure B illustrates an embodiment in which the height 71h of the base region 71 is greater than the height 64h of the uppermost bars 64a and 64b. Such embodiments are preferred if the separator comb 70 needs to be removed again before resin infusion. In such embodiments, the protrusion 76 of the base region 71 can be used to identify and grasp the separator comb 70 and remove it from the layered structure 61 before resin infusion. Alternatively, a separate protrusion or handle 76 can be attached to the base region 71 to achieve the same effect.

[0120] Figure 7 A is a schematic illustration of a partition structure 78, which includes two partition combs 70 connected by plate-shaped connecting elements 77 arranged on top of the layered structure 61. In the illustrated embodiment, the partition structure 78 is substantially rack-shaped. Figure 7 B is a schematic cross-sectional view of the layered structure 61 in which the partition structure 78 is arranged. The features of the partition comb 70 are the same as described with respect to the above embodiment. The connecting element 77 can be used to connect a plurality of partition combs 70 for easy handling and / or removal from the layered structure 61 before resin infusion. However, the partition structure can also be infused with resin together with the layered structure 61.

[0121] This disclosure has been described with reference to preferred embodiments. However, the scope of the invention is not limited to the illustrated embodiments, and changes and modifications can be made without departing from the scope of the invention.

[0122] List of reference numerals 4 towers 6. Cabin 8 hubs 10 blades 14. Leaf tips 16. Leaf base 18. Predestined Fate 20 trailing edge 30 Root region 32 Transition Zone 34. Airfoil area 36 Pressure side shell section 38 Suction side shell section 40 Shoulders 42 Fiber layer 43 Sandwich Core Materials 45 Wing beam cap 46 Fiber layer 47 Sandwich Core Material 50 First shear web 51 core components 52 Skin layer 55 Second shear web 56. Sandwich core material of the second shear web 57 Skin layer of the second shear web 60 Filler Rope 61 Layered structure The height of the 61h layered structure 62 Reinforced Structure 62h Height of the reinforced structure Thickness of the 62t reinforced structure 62l Length of the reinforcing structure 63 items Height of 63h bar Thickness of 63t strip 63l length 64a, b, c Top bar 64h Height of the top bar The thickness of the top bar is 64t. 64l is the length of the top bar. Stacking of 65a, b, and c The stacking height of 65h strips Thickness of 65t stacked strips The length of the stack of 65l strips 66 Intermediate Layer 67 Fiber-reinforced layer for enhanced structure 68. Topmost fiber reinforcement layer 68h Height of the uppermost fiber reinforcement layer 70 Divider Comb 70h Height of the dividing comb Thickness of 70t separator comb 70L length of the separator comb 71. Base Area 71h Base region height Thickness of the 71t base region 71l Length of the base region 72 The edge of the basal region furthest from the tooth tip 73-tooth region Height of the 73h tooth region 73l length of the tooth region 74 teeth 74h tooth height 74t tooth thickness 74l tooth length 75 Tooth tips 76. Handle or pultruded element 77 Connecting elements 78. Separation Structure 79. Gap of the dividing comb 80 The edge of the basal region closest to the tooth tip r is the distance from the hub.

Claims

1. A method for manufacturing a reinforcing structure (62) for a wind turbine blade, the method comprising the steps of: Multiple strips (63, 64) of fiber-reinforced material are arranged into adjacent stacks (65) forming a layered structure with multiple fiber-reinforced layers, wherein adjacent fiber-reinforced layers are separated by an intermediate layer. At least one separator comb (70) is provided, said at least one separator comb (70) comprising: - Base region (71) - A tooth region (73), said tooth region (73) including a plurality of teeth (74) extending from said base region (71), - wherein the plurality of teeth are arranged in a linear array with gaps between adjacent teeth, the gaps being configured to allow resin to flow from one side of the separator comb (70) to the other side of the separator comb (70), and wherein the plurality of teeth are configured to penetrate the intermediate layer. The at least one separator comb (70) is inserted between two adjacent stacks (65) of strips (63, 64) and penetrates the plurality of intermediate layers with the plurality of teeth, such that the plurality of strips (63, 64) in adjacent stacks of strips (63, 64) are separated by the at least one separator comb (70). After inserting at least one separator comb (70) between adjacent stacks of strips (63, 64), the layered structure can optionally be moved to a desired location, such as into a wind turbine blade shell mold. Optionally, the at least one separator comb (70) can be removed, and The layered structure is infused with resin to form a reinforcing structure (62).

2. The method according to any one of the preceding claims, wherein, The plurality of teeth (74) includes between 2 and 100 teeth, such as between 2 and 50 teeth, preferably between 5 and 10 teeth.

3. The method according to any one of the preceding claims, wherein, The gap between adjacent teeth in the plurality of teeth is between 3 mm and 200 mm, preferably between 3 mm and 50 mm, more preferably between 3 mm and 10 mm, such as 5 mm.

4. The method according to any one of the preceding claims, wherein, The layered structure has a height, and wherein the tooth region (73) of the at least one dividing comb (70) has a height equal to or greater than the height of the layered structure minus the height of the uppermost fiber reinforcement layer among the plurality of fiber reinforcement layers.

5. The method according to any one of the preceding claims, wherein, The at least one separator comb (70) has a height defined by the height of the tooth region (73) plus the height of the base region (71), and wherein the height of the at least one separator comb (70) is equal to or greater than the height of the layered structure, such that when the at least one separator comb is inserted between two adjacent stacks (65) of strips (63, 64) and penetrates the plurality of intermediate layers with the plurality of teeth, the plurality of strips (63, 64) in the adjacent stacks (65) of strips (63, 64) are separated by the at least one separator comb along the entire height of the layered structure.

6. The method according to any one of the preceding claims, wherein, The at least separating comb (70) is made of one or more fiber-reinforced materials and / or one or more metals and / or one or more thermoplastic materials.

7. The method according to any one of the preceding claims, wherein, The at least one separator comb (70) is substantially composed of fiber-reinforced carbon fibers and / or glass fibers.

8. The method according to any one of the preceding claims, wherein, The intermediate layer is a resin flow promoting intermediate layer configured to facilitate resin flow between the strips (63, 64) of the fiber-reinforced material, and wherein the step of infusing resin into the layered structure includes enabling resin flow from at least one of the stacks (65) of the strips (63, 64) to adjacent stacks of the strips (63, 64) through the gaps between adjacent teeth in the plurality of teeth through one or more of the intermediate layers.

9. The method according to any one of the preceding claims, wherein, The reinforcing structure (62) is a spar cap for a wind turbine blade, and the plurality of strips (63, 64) of fiber-reinforced material are pultruded thick plates comprising fiber-reinforced carbon fibers and / or glass fibers.

10. A method of manufacturing a wind turbine blade including a reinforcing structure (62), the wind turbine having a shaped profile including a pressure side and a suction side, and a leading edge and a trailing edge, wherein a chord having a chord length extends between the leading edge and the trailing edge, the wind turbine blade extending in the spanwise direction between a root tip and a tip tip, the method comprising the steps of: Provide blade shell molds, Multiple blade shell assemblies are arranged in the blade shell mold. Assembling the layered structure in the blade shell mold or assembling the layered structure at a location different from the blade shell mold and subsequently moving the layered structure to the blade shell mold, wherein the assembly of the layered structure includes: Multiple strips (63, 64) of fiber-reinforced material are arranged into adjacent stacks (65) forming a layered structure with multiple fiber-reinforced layers, wherein adjacent fiber-reinforced layers are separated by an intermediate layer. At least one separator comb (70) is provided, said at least one separator comb (70) comprising: - Base region (71) - A tooth region (73), said tooth region (73) comprising a plurality of teeth (74) extending from said base region, - wherein the plurality of teeth are arranged in a linear array with gaps between adjacent teeth, the gaps being configured to allow resin to flow from one side of the separator comb (70) to the other side of the separator comb, and wherein the plurality of teeth are configured to penetrate the intermediate layer. The at least one separator comb is inserted between two adjacent stacks of the strip and penetrates the plurality of intermediate layers with the plurality of teeth, such that the plurality of strips (63, 64) in adjacent stacks of the strip are separated by the at least one separator comb along the entire height of the layered structure. Optionally, the at least one separator comb can be removed, and Resin is infused into the blade shell mold to form a resin-infused reinforcing structure (62) in the wind turbine blade shell, and Two wind turbine blade shells are combined to form a wind turbine blade.

11. A reinforcing structure (62) for a wind turbine blade, the reinforcing structure (62) comprising a plurality of strips (63, 64, 65) of fiber-reinforcing material, the plurality of strips of fiber-reinforcing material being arranged in an adjacent stack (66) of strips forming a layered structure having a plurality of fiber-reinforcing layers. A plurality of intermediate layers are disposed between the plurality of fiber reinforcement layers such that adjacent fiber reinforcement layers are separated by intermediate layers. At least one dividing comb (70) is arranged between adjacent stacks of strips. in, The at least one separator comb (70) includes: - Base region (71) - A tooth region (73), said tooth region (73) comprising a plurality of teeth (74) extending from said base region, - Wherein, the plurality of teeth are arranged in a linear array with gaps between adjacent teeth, the gaps being configured to allow resin to flow from one side of the separator comb (70) to the other side of the separator comb (70), and - Wherein, the plurality of teeth penetrate the plurality of intermediate layers.

12. The reinforcement structure according to claim 11, wherein, The plurality of strips, the plurality of intermediate layers and the at least one separator comb (70) are embedded in the cured resin.

13. A wind turbine blade comprising one or more reinforcing structures according to any one of claims 11 or 12.

14. A separator comb (70) configured to separate adjacent stacks of strips (63, 64) having multiple fiber-reinforced layers forming a sparsity cap for a wind turbine blade, wherein, Adjacent fiber reinforcement layers in the plurality of fiber reinforcement layers are separated by an intermediate layer. The separator comb (70) includes: - Base region (71) - A tooth region (73) comprising a plurality of teeth (74) extending from the base region, wherein the tooth region has a height equal to or greater than the height of the spar cap minus the height of the uppermost fiber reinforcement layer among the plurality of fiber reinforcement layers. - Wherein, the plurality of teeth are arranged in a linear array with gaps between adjacent teeth, the gaps being configured to allow resin to flow from one side of the separator comb (70) to the other side of the separator comb (70), and - wherein the plurality of teeth are configured to penetrate the intermediate layer.

15. A partition structure comprising at least two partition combs according to any one of the preceding claims, wherein, The at least two separator combs are connected by connecting elements.

16. A component (62) for a wind turbine blade, said component comprising a separator comb (70) and a plurality of stacked fiber reinforcement layers, wherein, The separator comb (70) includes a base region (71) and a tooth region (73), the tooth region (73) including a plurality of teeth (74) extending from the base region (71), and wherein the plurality of teeth of the tooth region of the separator comb (70) penetrate the plurality of stacked fiber reinforcement layers.

17. The component for a wind turbine blade according to claim 16, wherein, The plurality of teeth (74) are arranged in a linear array with gaps between adjacent teeth, the gaps being configured to allow resin to flow from one side of the separator comb (70) to the other side of the separator comb (70).

18. The component for a wind turbine blade according to claim 16 or 17, wherein, The plurality of stacked fiber reinforcement layers include adjacent stacks of fiber reinforcement layers forming a spar cap for a wind turbine blade, wherein the fiber reinforcement layers within each of the stacks are separated by an intermediate layer, and wherein the tooth region (73) has a height equal to or greater than the height of the spar cap minus the height of the uppermost fiber reinforcement layer among the plurality of stacked fiber reinforcement layers.

19. The component for a wind turbine blade according to claim 18, wherein, The plurality of teeth are configured to penetrate the intermediate layer.

20. The component for a wind turbine blade according to any one of claims 16 to 19, wherein, The component includes at least two separator combs according to any one of the preceding claims, wherein the at least two separator combs are connected by a connecting element.

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