Sspar cap structure including lightning connector assembly and conductive assembly

Abstract

In a first aspect, a spar cap structure for a wind turbine blade is provided. The spar cap structure includes a body, a lightning connector assembly, and a conductive assembly. The body includes a first side and a second side, wherein the body includes a plurality of layers of one or more carbon fiber members. A lightning component is disposed at one of the sides of the body and extends a height from the outer end to the inner end in a direction substantially parallel to the thickness of the body. A conductive assembly extends from the body to the lightning connector assembly to electrically connect the body to the lightning connector assembly. In another aspect, a wind turbine blade is provided that includes one or more spar cap structures according to any of the examples herein. In still another aspect, a method for manufacturing a spar cap structure and a wind turbine blade according to any of the examples herein is provided.

Description

Technical Field

[0001] This disclosure relates to a spar cap structure comprising a body, a lightning connector assembly, and a conductive assembly. This disclosure further relates to wind turbine blades including spar cap structures, and methods for manufacturing these spar cap structures and these wind turbine blades. Background Technology

[0002] Modern wind turbines are typically used to supply electricity to the grid. This type of wind turbine generally consists of a rotor with a hub and multiple turbine blades. The rotor begins to rotate under the influence of wind on the blades. The rotation of the rotor shaft is either directly (“directly driven”) or driven by a generator rotor using a gearbox. The gearbox (if present), generator, and other systems are typically housed in a nacelle atop the wind turbine tower.

[0003] Wind turbine blades are generally made of fiber-reinforced polymer or plastic (FRP), a composite material consisting of a polymer matrix reinforced with fibers. The fibers are typically glass or carbon and provide longitudinal stiffness and strength.

[0004] Wind turbine blades are typically manufactured by joining two blade shell sections made of fiber-reinforced polymers, such as glass fiber reinforced polymers or carbon fiber reinforced polymers. These blade shell sections can be molded using resin infusion or prepreg techniques. In resin infusion, fibers are placed in a mold, and resin is then injected into the mold cavity under pressure. The resin fills the volume between the cavities, and then the resin cures or hardens. Examples of resin infusion techniques include resin transfer molding (RTM) or vacuum-assisted resin transfer molding (VARTM). In VARTM, the resin is injected under vacuum or pressure below atmospheric pressure.

[0005] A load-bearing structure may be arranged between the pressure-side blade shell portion and the suction-side blade shell portion. The load-bearing structure may include reinforcing structures with opposing spars attached to the respective blade shell portions. The spars may be embedded within the composite laminate of the blade shell portion or laminated to the inner surface of the blade shell. The spars serve to receive reinforcing structures, such as a pair of opposing flanges, and to structurally reinforce the wind turbine blade. Providing spars in the blade shell portion typically improves the stiffness, buckling resistance, and strength of the wind turbine blade. The spars extend along the longitudinal length of the wind turbine blade.

[0006] The spar cap can be made of various materials, including glass fiber laminates and carbon fiber laminates. For example, glass fiber fabrics or carbon fiber fabrics can be used to manufacture the spar cap. Pultrusion composites can be used alternatively to improve mechanical properties. A pultrusion composite or pultruded part is a fiber-reinforced material impregnated with resin and pulled through a heated static die, causing the resin to cure and undergo polymerization. Pultrusion composites can include carbon fiber pultruded parts and / or glass fiber pultruded parts. Thus, the pultrusion process is typically characterized as a continuous process producing composite sections with a constant cross-section. Therefore, multiple pultruded parts can be vacuum-injected together in a die to form the spar cap. The pultruded parts are prefabricated, which allows for a high level of quality, as well as better fiber structure and uniformity.

[0007] Recently, there has been a trend towards increasing the size of wind turbine blades to capture more wind. Larger blades typically involve higher mechanical requirements. Furthermore, manufacturing complexity increases with blade size. Carbon fiber (e.g., carbon fiber pultrusions) offers a better stiffness-to-weight ratio and fatigue resistance than glass fiber (e.g., glass fiber pultrusions). Therefore, carbon fiber (e.g., carbon fiber pultrusions) can be used to meet these high mechanical requirements. For this purpose, carbon fiber pultrusions can be used to manufacture spar cap structures.

[0008] Furthermore, as the size of wind turbine blades increases, the risk of lightning strikes on them also increases. Wind turbine blades can be equipped with lightning receivers to capture lightning strikes. These lightning receivers are electrically connected to downconductors arranged within the wind turbine blades to conduct the lightning current to the ground. These lightning receivers are arranged on the outside of the spar cap structure made of carbon fiber components. The lightning receivers are generally arranged in the glass fiber of the blade shell portion, for example, in the core structure outside the spar cap structure.

[0009] Carbon fiber has a higher conductivity than glass fiber. A lightning strike on carbon fiber can cause it to conduct lightning current. However, the resin binding the carbon fiber layers (e.g., several carbon fiber pultrusions) has lower conductivity. Therefore, any gaps between the resin and the carbon fiber layers can impede the flow of lightning current between the carbon fiber layers (e.g., carbon fiber pultrusions). This can create a risk of internal flashover between the carbon fiber layers (which can potentially damage the material). To address this, thin conductive yarns can be provided between the layers of the carbon fiber component, such as between carbon fiber pultrusions. These thin conductive yarns have a higher conductivity than the resin. These conductive yarns can be electrically connected to a down conductor.

[0010] Installing the lightning receiver within the core structure and connecting it to the conductive yarn arranged between carbon fiber components (e.g., carbon fiber pultrusions) in the spar cap is complex and requires several elements. Copper elements are generally, at least partially, arranged on the inner side of the core structure, extending from the spar cap. Some of these copper elements are used to connect the conductive yarn to the down conductor. These copper elements are generally arranged on the inner side of the blade shell and are separate from the spar cap.

[0011] For example, a structure called a lightning protection ear can be made of copper mesh. These lightning protection ears can extend from the spar cap and can be arranged on the inside of the core structure. Using these lightning protection ears may involve using interconnecting cables that are connected to the lightning protection ears via copper discs attached to them. These interconnecting cables connect the lightning protection ears to the down conductor.

[0012] Conductive yarns can be bonded to the copper mesh after the spar cap is manufactured. These copper meshes can be damaged or detached from the spar cap when it is transferred from the spar cap mold to the blade shell mold. Furthermore, aligning these copper meshes with the shell (e.g., the core structure) is difficult. Additionally, because the copper mesh or lightning protection ears are located on the inside of the core structure, it is difficult to detect damage or misalignment of the copper mesh or lightning protection ears by inspection from the outside of the wind turbine blade (e.g., by ultrasonic inspection). Moreover, the adhesion between the lightning protection ears or copper mesh and the blade shell is generally poor. The adhesion between the copper disc and the copper mesh is also generally poor.

[0013] In other examples, the copper components are arranged inside the core structure. Installing these components onto the core structure requires precision machining. Therefore, these operations are both complex and time-consuming. Furthermore, machining the core structure to house the copper components and the lightning receivers of the lightning protection system can weaken the core structure. Consequently, the structural integrity of the wind turbine blades can be adversely affected. In these examples, the connection between the conductive yarn and the copper components is also complex. The adhesion between the copper components and the core structure may also be poor.

[0014] This disclosure provides examples of systems and methods that at least partially address some of the drawbacks mentioned above. Summary of the Invention

[0015] In a first aspect, a spar cap structure for a wind turbine blade is provided. The spar cap structure includes a body, a lightning connector assembly, and a conductor assembly.

[0016] The main body includes a first side and a second side. Furthermore, the main body comprises one or more multi-layered carbon fiber components. Each of these layers is arranged one on top of another to define the thickness of the main body between the first and second sides.

[0017] The lightning connector assembly is located at one of the sides of the body. The lightning assembly extends from the outer end to the inner end in a direction substantially parallel to the thickness of the body. The outer end is configured to connect to a lightning receiver, and the inner end is configured to connect to the down conductor of the lightning protection system for the wind turbine blades.

[0018] The conductive component extends from the body to the lightning connector assembly to electrically connect the body to the lightning connector assembly.

[0019] According to this aspect, the lightning receiver components can be integrally integrated into the spar cap structure. Therefore, the accuracy and precision of the manufacturing process can be improved. The use of some lightning protection elements (such as lightning protection lugs or copper discs) is eliminated. As a result, problems related to the arrangement and bonding of these lightning protection elements within the blade shell are resolved. Furthermore, since the lightning connector assembly is located within the spar cap structure (and not in the core structure near the spar cap), the lightning connector assembly can be inspected from the outside of the wind turbine blade. Therefore, ultrasonic methods can be used. This allows for improved reliability in blade manufacturing.

[0020] Because the lightning connector assembly is located within the spar cap structure, the electrical connection between the carbon fiber body and the lightning connector assembly is simplified. Therefore, the electrical connection between the body and the lightning connector assembly via the conductive assembly can be performed before the entire wind turbine blade is formed. This allows for a reduction in the number of components and avoids certain post-processing tasks, such as machining the blade shell to install a typical copper disc and welding the body to the lightning receiver. Current can then flow from the carbon fiber body through the conductive assembly to the lightning connector assembly. The current can then be conducted towards the downconductor.

[0021] Furthermore, the installation of the lightning receiver is simplified because it can be attached to the outer end of the lightning connector assembly. Therefore, it is not necessary to insert the lightning receiver through the entire thickness of the core structure from the outside of the spar cap structure. Consequently, the lightning protection system can be assembled in a much easier manner.

[0022] Furthermore, the processing steps for placing the spar cap in the blade shell mold are simplified. This further prevents lightning elements (such as lightning protection ears) from separating from the blade shell, for example, from the spar cap or from the core structure.

[0023] In another aspect, a wind turbine blade extending in a longitudinal direction is provided. The wind turbine blade includes an upper blade shell portion and a lower blade shell portion connected to the upper blade shell portion. The wind turbine blade further includes a reinforcing structure between the upper blade shell portion and the lower blade shell. Additionally, the upper blade shell portion and / or the lower blade shell portion include a sparsus cap structure according to any example disclosed in the examples herein.

[0024] In another aspect, a method for manufacturing a spar cap structure is provided. This method involves forming a body by stacking one or more layers of carbon fiber members to define a thickness between a first side and a second side of the body.

[0025] Additionally, the method includes arranging a lightning connector assembly on one side of the body. The lightning connector assembly extends from an outer end to an inner end in a direction substantially parallel to the thickness of the body. The outer end is configured to connect to a lightning receiver, and the inner end is configured to connect to a down conductor of a lightning protection system for wind turbine blades.

[0026] The method further includes arranging a conductive component to extend from the body to the lightning connector assembly for electrically connecting the body to the lightning connector assembly. Additionally, the method includes attaching the lightning connector assembly to the body.

[0027] In another aspect, a method for manufacturing a wind turbine blade according to any of the examples disclosed herein is provided. The method for manufacturing a wind turbine blade includes forming an upper blade shell portion and a lower blade shell.

[0028] Forming the upper blade shell portion and / or the lower blade shell portion includes arranging a spar cap structure on the outer layer laid in the mold of the blade shell portion, and incorporating the spar cap structure into the outer layer.

[0029] The method for manufacturing a wind turbine blade further includes: connecting a reinforcing structure to an upper blade shell portion and to a lower blade shell portion, such that the reinforcing structure is arranged between the upper blade shell portion and the lower blade shell portion, and connecting the upper blade shell portion to the lower blade shell portion.

[0030] The advantages gained from these aspects are similar to those mentioned regarding the first aspect. Attached Figure Description

[0031] Non-limiting examples of this disclosure will be described below with reference to the accompanying drawings, in which: Figure 1 A perspective view of a wind turbine based on an example is shown; Figure 2 A perspective view of a wind turbine blade based on an example is shown; Figure 3 A cross-sectional view of a wind turbine blade according to an example of this disclosure is shown; Figure 4A A cross-sectional view of a sparsus cap structure arranged in a wind turbine blade according to an example of the present disclosure is schematically presented; Figure 4B A cross-sectional view of a sparsus cap structure arranged in a wind turbine blade according to another example of this disclosure is schematically presented; Figure 4C A cross-sectional view of a sparsus cap structure arranged in a wind turbine blade according to another example of this disclosure is schematically presented; Figure 5 An isometric view of a portion of a spar cap structure according to an example of this disclosure is schematically presented; Figure 6A and Figure 6B An example of a portion of a wing cap structure according to one embodiment of this disclosure is schematically presented; Figure 7A and Figure 7B An example of a conductive element according to this disclosure is illustrated schematically; Figure 8A and Figure 8B An example of an isometric view schematically presented of a portion of the spar cap structure according to this disclosure; Figure 9 This is a block diagram of a method for manufacturing a spar cap structure according to an example of this disclosure; and Figure 10 This is a block diagram of a method for manufacturing a wind turbine blade according to an example of this disclosure. Detailed Implementation

[0032] In these figures, the same reference numerals have been used to denote matching elements.

[0033] Figure 1 A perspective view of an example wind turbine 1 is shown. As shown, the wind turbine 1 includes a tower 2 extending from a support surface 3, a nacelle 4 mounted on the tower 2, and a rotor 5 coupled to the nacelle 4. The rotor 5 includes a rotatable hub 6 and at least one wind turbine blade 7 coupled to and extending outward from the rotor hub 6. For example, in the example shown, the rotor 5 includes three wind turbine blades 7. However, in alternative examples, the rotor 5 may include more or fewer than three blades 7. Each wind turbine blade 7 may be spaced apart from the rotor hub 6 to allow the rotor 5 to rotate, enabling the conversion of kinetic energy from the wind into usable mechanical energy, and subsequently into electrical energy. For example, the rotor hub 6 may be rotatably coupled to a generator located within or forming part of the nacelle 4 to allow the generation of electrical energy.

[0034] Figure 2An example of a wind turbine blade 7 is shown. The wind turbine blade 7 extends from the blade root end 71 to the blade tip end 72 along a longitudinal direction or longitudinal direction 37. The blade 7 includes a blade root region or portion 50 closest to the rotor hub, a profiled or airfoil portion 52 furthest from the rotor hub, and a transition portion 51 between the blade root portion 50 and the airfoil portion 52. The blade 7 includes a leading edge 53 facing the direction of rotation of the blade 7 when mounted on the rotor hub, and a trailing edge 54 facing the opposite direction to the leading edge 53.

[0035] The airfoil portion 52 has a shape designed to generate lift, while the blade root portion 50 has a circular or elliptical cross-section for structural reasons and ease of blade mounting to the rotor hub. The diameter or chord of the blade root portion 50 can be constant along its entire length. At the transition portion 51, the profile gradually changes from the circular or elliptical cross-section of the blade root portion 50 to the airfoil profile of the airfoil portion 52. The wind turbine blade 7 can be connected to the rotor hub via the blade root attachment portion 55.

[0036] The wind turbine blade 7 includes a blade shell 73. The blade shell 73 includes an outer or outer surface that defines the external shape of the blade (e.g., the external shape at the blade root portion and the external shape at the airfoil portion). The blade shell 73 also includes an inner or inner surface (not shown) that defines the internal volume of the blade and faces the load-bearing structure. The blade shell 73 may be made of fiber-reinforced polymers or plastics, such as glass fiber and / or carbon fiber.

[0037] The blade shell can be formed from multiple blade shell portions. Multiple blade shell portions can be joined together to form the blade shell. The blade shell portions can be formed and then joined according to any of the examples disclosed herein. Resin infusion techniques (such as RTM or VARTM) or prepreg techniques can be used to manufacture the blade shell portions.

[0038] In some examples, the blade shell includes a lower blade shell portion and an upper blade shell portion. The lower blade shell may be a pressure-side blade shell portion. The upper blade shell portion may be a suction-side blade shell portion. The lower blade shell portion may be connected to the upper blade shell portion along connecting lines, along leading edge 53 and trailing edge 54. Each of these blade shell portions may be manufactured in a mold and then joined together to define the entire blade shell of the wind turbine blade 7. Reinforcing structures are arranged between the lower blade shell portion and the upper blade shell portion.

[0039] Figure 3A cross-sectional view of a wind turbine blade 7 according to an example of this disclosure is shown. A suction-side blade shell portion or upper blade shell portion 100 and a pressure-side blade shell portion or lower blade shell portion 200 extend from a leading edge 53 to a trailing edge 54. The wind turbine blade 7 further includes a chord 38 between the leading edge 53 and the trailing edge 54. The chord 38 extends in a lateral or chordal direction. A flapping direction 39 is substantially perpendicular to the chord 38. The upper blade shell portion 100 and the lower blade shell portion 200 are connected (e.g., joined) together along the leading edge 53 and the trailing edge 54.

[0040] The upper blade shell portion 100 includes an outer upper layer 101 and an inner upper layer 102. The outer upper layer 101 defines the external shape of the upper blade shell portion 100, and the inner upper layer 102 defines the internal shape of the upper blade shell portion 100. The outer upper layer 101 and the inner upper layer 102 may comprise glass fiber laminates. For example, one or more glass fiber laminates may be arranged to form the outer upper layer 101 and / or the inner upper layer 102. The fibers (e.g., glass fibers) may be bidirectionally oriented to enhance the torsional stiffness of the blade 7. In other examples, the fibers may be unidirectionally arranged. In further examples, the upper layers 101 and / or 102 comprise laminates having unidirectional fibers and laminates having bidirectional fibers.

[0041] The upper blade shell portion 100 of this example includes an upper wing sparsor structure 110 embedded between the upper outer layer 101 and the upper inner layer 102. Therefore, the upper wing sparsor structure 110 is arranged between the upper outer layer 101 and the upper inner layer 102. The upper wing sparsor structure 110 structurally reinforces the upper blade shell portion 100.

[0042] In some portions of the upper blade shell portion 100, a core structure may be arranged between the upper outer layer 101 and the upper inner layer 102. For example, a portion of the core structure may extend between the upper spar cap structure 110 and the leading edge. Alternatively, a portion of the core structure may extend between the upper spar cap structure 110 and the trailing edge 54. The core structure generally increases the thickness of the blade shell portion to improve stiffness without adding excessive weight. The core structure may be made of lightweight materials, such as balsa wood or polymer foam.

[0043] The lower blade shell portion 200 may be manufactured similarly to the upper blade shell portion 100. As described with reference to the upper blade shell portion 100, the lower blade shell portion 200 includes a lower outer layer 201 and a lower inner layer 202. The lower outer layer 201 and / or the lower inner layer 202 may comprise biaxially oriented glass fibers. A lower spar cap structure 210 is embedded between the lower outer layer 201 and the lower inner layer 202.

[0044] In this example, the upper spar cap structure 110 and the lower spar cap structure 210 span the flapping direction 39. The spar cap structures 110 and 210 are opposite each other. The spar cap structures 110 and 210 may extend in length along the spanwise direction 37 of the wind turbine blade. The length of the spar cap structure may be greater than 90% of the total length of the wind turbine blade.

[0045] The spar cap structures 110 and 210 may be based on any of the examples in this document. The spar cap structure of this example includes a body comprising carbon fiber. The carbon fibers are arranged in layers to form carbon fiber components.

[0046] In some examples, the body portion may include layers of carbon fiber fabric. Thus, layers formed of carbon fiber fabric are arranged one on top of another to define the thickness of the body. In these examples, the carbon fiber component is carbon fiber fabric.

[0047] In other examples, the body may include multiple carbon fiber pultruded parts. The carbon fiber pultruded parts may be arranged to form several rows of carbon fiber pultruded parts. Multiple pultruded parts may be arranged side-by-side to form a row of carbon fiber pultruded parts. In these examples, the carbon fiber component is a carbon fiber pultruded part.

[0048] The spar cap structures 110 and 210 of this figure include a lightning connector assembly disposed on one side of the body and a conductive assembly extending from the body to the lightning connector assembly. Thus, an electrical path can be created from the body to the lightning connector assembly. Therefore, electrical connection of the spar cap to the downconductor can be easily performed. The conductive assembly may include metal conductive elements and / or carbon fiber elements.

[0049] The spar cap structures 110 and 210 are prefabricated. The body, lightning connector assembly, and metal conductive assembly can be combined, for example, by injection molding, before being placed on a blade shell mold for manufacturing the corresponding blade shell portion. Prefabricated spar cap structures 110 and 210 simplify the electrical connection between the carbon fiber body and the lightning receiver assembly.

[0050] The wind turbine blade 7 includes a reinforcing structure 300 disposed between the upper blade shell portion 100 and the lower blade shell portion 200. The reinforcing structure 300 provides stiffness to the wind turbine blade. The reinforcing structure 300 includes a first reinforcing beam 310 disposed between the upper spar cap structure 110 and the lower spar cap structure 210. In another example, the reinforcing structure includes a first reinforcing beam and a second reinforcing beam.

[0051] In this example, the first reinforcing beam 310 extends along the spanwise direction 37. The first reinforcing beam 310 may extend substantially between the root portion and the tip portion. The length of the first reinforcing beam 310 may correspond to the lengths of the wing cap structures 110 and 210.

[0052] The first reinforcing beam 310 includes a web 340 extending between an upper flange 320 and a lower flange 330. The upper flange 320 of the first reinforcing beam 310 is connected to the upper blade shell portion 100. The upper flange 320 is connected (e.g., bonded) to the upper inner layer 102 in the area of ​​the upper spar cap structure 110. Similarly, the lower flange 330 is connected to the lower inner layer 202 in the area of ​​the lower spar cap structure 210. In this example, the first reinforcing beam 310 and the spar cap structures 110 and 210 form a load-bearing structure for the wind turbine blade, which is used to withstand the loads applied to the wind turbine blade.

[0053] In this example, the first reinforcing beam 310 comprises a single web. However, in other examples, the first reinforcing beam 310 may comprise two webs extending between flanges 320 and 330. This configuration may be broadly referred to as a spar box configuration.

[0054] An adhesive layer may be disposed between flanges 320 and 330 and the corresponding inner layers 102 and 202. The adhesive layer connects flanges 320 and 330 to blade shell portions 100 and 200. Therefore, the first reinforcing beam 310 may be attached to the upper blade shell portion 100 and to the lower blade shell portion 200. Spallation cap structures 110 and 210 are disposed between the corresponding flanges 320 and 330 and the outer layers 101 and 201.

[0055] Figure 4A A cross-sectional view of a sparsor cap structure arranged in a wind turbine blade 210 according to an example of this disclosure is schematically presented. The figure shows a sparsor cap structure (lower sparsor cap) arranged in the lower blade shell portion; however, a sparsor cap (upper sparsor cap) arranged in the upper blade shell portion may be based on any example of the lower sparsor cap disclosed herein.

[0056] In this example, the spar cap structure 210 is arranged between the lower outer layer 201 and the lower inner layer 202. The spar cap structure includes a body 220 extending between a first side 221 and a second side 222. In this example, the first side 221 is the leading edge side, and the second side 222 is the trailing edge side; however, in other examples, the opposite may be true. The body 220 includes a thickness extending in a direction substantially perpendicular to the waving direction 39 (i.e., extending between the lower outer layer 201 and the lower inner layer 202).

[0057] The body 220 is formed of multiple layers of carbon fiber members arranged in a layer on top of another layer. In this example, the carbon fiber members are carbon fiber pultruded parts 231. The body 220 includes rows of carbon fiber pultruded parts 231. The body 220 in this example includes four rows of carbon fiber pultruded parts 231, with three carbon fiber pultruded parts 231 in each row. In some examples, the number of carbon fiber pultruded parts 231 may vary along the spanwise direction 37 of the blade. The body 220 may include any suitable number of carbon fiber pultruded parts 231. In other examples, layers may be formed by directly placing fibers (e.g., in the form of fabric).

[0058] The carbon fiber pultruded part 231 in this example is a sheet. The width of the pultruded sheet is a multiple of its thickness, for example, more than ten times. In some examples, the pultruded sheet includes a width between 20 mm and 300 mm, and a thickness between 1 mm and 6 mm (e.g., 5 mm). In other examples, the pultruded part includes other suitable cross-sectional shapes, such as a rectangular cross-section.

[0059] The main body 220 can extend along the length of the corresponding spar cap structure 210 in a direction parallel to the spanwise or longitudinal direction 37 of the wind turbine blade. In some examples, the length of each row or layer of pultruded members varies along the spanwise direction to form a stepped structure. In other examples, some pultruded members in a row or layer can extend the entire length of the spar cap structure.

[0060] The body 220 in this example is made of carbon fiber pultruded part 231. The carbon fibers in these pultruded parts are arranged in a unidirectional configuration. In other examples, the body may have a hybrid configuration: a carbon fiber pultruded part and other types of fiber pultruded parts, such as glass fiber pultruded parts and / or aramid fiber pultruded parts. In some examples, the carbon fiber pultruded part may include copper portions. For example, copper portions may be arranged on each side of the carbon fiber pultruded part. These copper portions enhance the electrical connectivity of the carbon fiber pultruded part.

[0061] The body 220 of this example includes a conductive foil or yarn 232 disposed between two consecutive rows of the pultruded part. The conductive yarn 232 may extend at least the width of a layer or row of the carbon fiber pultruded part 231. In this example, the conductive yarn 232 extends from a first side 221 to a second side 222. In some examples, the conductive yarn 232 has a thickness of less than 0.5 mm, for example, 0.05 mm and 0.45 mm.

[0062] In some examples, the conductive yarn 232 may comprise carbon fibers and / or metals, such as copper and / or steel. In some examples, the conductive yarn 232 comprises carbon fibers (e.g., in the form of carbon fiber fabric) and / or metal conductive filaments. The carbon fibers may be arranged in a biaxial configuration. Alternatively or additionally, the conductive yarn 232 may comprise copper filaments. In further examples, the conductive yarn 232 may comprise a hybrid fiber configuration, such as a glass / carbon fiber fabric or woven material.

[0063] The resin material can be arranged between two consecutive layers or rows of the carbon fiber pultruded part 231. The conductivity of the conductive yarn 232 is greater than that of the resin material.

[0064] In this example, each conductive yarn 232 is sandwiched between two consecutive carbon fiber pultrusions. Alternatively or additionally, the conductive yarn 232 or copper mesh may be arranged on the top and / or bottom of the body 220.

[0065] The spar cap structure 210 further includes a lightning connector assembly 240. In this example, the lightning connector assembly 240 is disposed at a second side 222 of the body, i.e., at the trailing edge side of the body 220. In other examples, the lightning connector assembly 240 may be disposed at the leading edge side.

[0066] The Lightning connector assembly 240 extends from an outer end 241 to an inner end 242 in a direction substantially parallel to the thickness of the body 220. The outer end 241 is disposed near the lower outer layer 201, and the inner end 242 is near the lower inner layer 202. In this example, the height of the Lightning connector assembly 240 substantially corresponds to the thickness of the body 220. In other examples, the height of the Lightning connector assembly 240 may be greater than or less than the thickness of the body 220.

[0067] In some examples, the Lightning connector assembly 240 includes a plurality of elongated connectors distributed along the longitudinal direction 37 of the spar cap structure 210. The height of the elongated connectors (i.e., between the outer end 241 and the inner end 242) is greater than their length along the longitudinal direction 37. In other examples, the Lightning connector assembly 240 includes strip connectors or multiple strip connectors extending along the longitudinal direction 37 of the spar cap structure 210. The length of the strip connectors is greater than their height. The Lightning connector assembly 240 may include a metallic conductor, such as copper.

[0068] In this example, the lightning receiver 400 is connected to the outer end 241 of the lightning connector assembly 240. In this example, the lightning receiver 400 passes through the outer layer 201 and is inserted into a hole disposed at the outer end 241 of the lightning receiver 400. Therefore, the lightning receiver 400 is electrically connected to the lightning connector assembly 240. This hole may be a threaded hole to thread the upper end of the lightning receiver 400. The lightning receiver 400 in this example includes an outer portion disposed on the outside of a wind turbine blade to capture lightning strikes. The lightning receiver 400 in this figure comprises a substantially T-shape.

[0069] The wind turbine blade in this example further includes a down conductor 410 extending substantially parallel to the longitudinal direction 37. The down conductor 410 may extend substantially the entire length of the wind turbine blade 7. The down conductor 410 is configured to be electrically connected to the ground in order to conduct lightning current to the ground.

[0070] In this example, the down conductor 410 is supported by the web 340 of the first reinforcing beam 310. In other examples, the down conductor 410 may be connected to the lower flange 330 or the upper flange of the first reinforcing beam 310.

[0071] In this example, cable 420 electrically connects the lightning connector assembly 240 to the down conductor 410. One end of the cable 420 is attached to the inner end 242 of the lightning connector assembly 240, for example, wound around a fastener 421 screwed onto the inner end 242 of the lightning connector assembly 240. The opposite end of the cable 420 is attached to the down conductor 410.

[0072] As can be seen in the figure, the lightning receiver 400 contacts the lightning connector assembly 240. Therefore, a current path can be created toward the downconductor 410.

[0073] In some examples, the wind turbine blade 7 includes multiple lightning receivers 400 connected to the outer end 241 of the lightning connector assembly 240. Multiple cables 420 can connect the inner end 242 of the lightning connector assembly 240 to the down conductor 410. Each of the cables 420 can be associated with a lightning receiver 400.

[0074] The spar cap structure 210 also includes a conductive assembly 280. The conductive assembly 280 extends from the body 220 to the lightning connector assembly 240. In this example, the metal conductive assembly 280 includes a conductive element 290 extending between a first end 291 and a second end 292. In this example, the first end 291 is connected to the lightning connector assembly 240, and the second end 292 is connected to a layer of carbon fiber material. In this example, the conductive element 290 includes a metal conductive element. In other examples, the conductive element 290 may include carbon fiber.

[0075] Therefore, the conductive yarn 232 can be electrically connected to the down conductor of the wind turbine blade in a simple manner via the conductive assembly 280 and the lightning connector assembly 240. Thus, the electrical connection between the conductive yarn 232 and the lightning protection system can be performed before the entire wind turbine blade is formed. This allows for a reduction in the number of components and prevents the need for post-operational tasks such as machining the blade housing to install a typical copper disc.

[0076] In this example, the conductive element 290 is distributed along the thickness of the body 220. In this figure, the conductive element 290 (e.g., a metal conductive element) is arranged between two rows of carbon fiber pultruded material 231. In this example, the second end 292 of the conductive element 290 is embedded in the corresponding conductive yarn 232. Therefore, the conductive element 290 is electrically connected to the conductive yarn 232. Thus, a current path can be established between the body 220 and the lightning connector assembly 240. In some examples, the first and second ends of the conductive element 290 may be integrally integrated within the conductive yarn 232. In these examples, a portion of the conductive yarn 232 protrudes from the body 220.

[0077] In some examples, the conductive assembly 280 may further include a plurality of conductive elements, such as metal conductive elements, distributed along the longitudinal direction 37 of the spar cap structure. Thus, the electrical connection between the body and the lightning connector assembly 240 can be further improved. Therefore, the conductive elements may be distributed at several heights relative to the body 220 and at several locations along the longitudinal direction 37.

[0078] In some examples, a conductive element 290 may include a metallic conductive element. The conductive element may include strands of conductive filaments (e.g., copper wire). A second end 292 of the stranded conductive filaments may be embedded in the conductive yarn 232. In other examples, a conductive element 290 may include a metallic conductive film, such as a copper film. The second end 292 of these metallic conductive films may be embedded in the conductive yarn 232. In yet another example, a first end 291 of the conductive element 290 may also be embedded in the conductive yarn 232.

[0079] The main body 220, the conductive assembly 280, and the lightning connector assembly 240 can be assembled before being placed on the blade shell mold. For example, these components can be cast together. In other examples, some of these components can be cast separately and then connected to each other to form a spar cap structure.

[0080] In another example, at least some of these components may be infused together with the blade shell in the blade shell mold.

[0081] In some examples, the conductive layer may be arranged to at least partially surround the body 220 and the lightning connector assembly 240. Electrical connections between the different components forming the spar cap structure 210 can be improved. In some examples, the spar cap structure 210 may be encapsulated by the conductive layer. The conductive layer may include a layer having carbon fibers arranged in a biaxial configuration. In other examples, other types of fibers may also be arranged in the conductive layer. In still other examples, the conductive layer may include a copper mesh.

[0082] Figure 4B A schematic cross-sectional view of a sparsus cap structure arranged in a wind turbine blade according to an example of this disclosure is presented. The sparsus cap structure 210 of this example is... Figure 4A The structure 210 is similar to the spar cap structure. For example, the lightning connector assembly 240 of this example may be based on any of the examples in this document. However, the body 220 of this example includes a copper mesh 233 arranged on top of the carbon fiber pultruded part 231.

[0083] Figure 4B A single conductive element 290 is depicted in the cross-sectional view. However, it should be recognized that the spar cap structure 210 may include multiple conductive elements 290 distributed along the longitudinal direction 37. A second end 292 of the conductive element 290 contacts the copper mesh 233. Therefore, the second end 292 overlaps with the copper mesh 233. The conductive element 290 in this example is a metallic conductive element. The metallic conductive element in this example may be a metallic conductive film, such as a copper film, or strands of metallic conductive wire (e.g., copper wire). The conductive element 290 may be arranged within the copper mesh 233. For example, conductive wire (e.g., metallic conductive wire) or carbon fiber is sewn together with the copper mesh 233.

[0084] In some examples, the conductive assembly 280 includes some conductive elements 290 in contact with the copper mesh 233 and other conductive elements 290 in contact with the conductive yarn 232.

[0085] Figure 4C A schematic cross-sectional view of a sparsus cap structure arranged in a wind turbine blade according to another example of this disclosure is presented. The body 220 of this example comprises multiple layers of carbon fiber components. The layers in this figure are carbon fiber fabric layers 235. The carbon fiber fabric layers 235 are arranged one on top of another. Each layer of the carbon fiber fabric layers 235 in this example extends from a first side 221 of the body 220 to a second side 222.

[0086] Furthermore, the body 220 includes a copper mesh 233 disposed on top of the carbon fiber fabric layer 235. The copper mesh 233 in this example may be based on any of the examples in this document.

[0087] In the cross-sectional view of this figure, the conductive assembly 280 includes conductive elements 290. However, it should be understood that multiple conductive elements 290 may be distributed along the longitudinal direction 37. In this example, the second end 292 of the conductive element 290 contacts the copper mesh 233. For example, the second end 292 of the conductive element 290 may be embedded within the copper mesh 233.

[0088] Alternatively or additionally, the conductive assembly may include conductive elements 290 distributed at different heights. The second end 292 of these conductive elements 290 may be embedded in a carbon fiber fabric layer 235 or between two consecutive carbon fiber fabric layers 235.

[0089] Figure 5 An isometric view schematically depicting a portion of a spar cap structure according to an example of this disclosure is shown. The body 220 of this example includes a plurality of carbon fiber pultruded members 231 arranged in rows. Conductive yarns 232 are arranged between two consecutive rows of carbon fiber pultruded members. The conductive yarns 232 and the carbon fiber pultruded members 231 may be according to any example in the examples herein.

[0090] In this example, the lightning connector assembly 240 is disposed at the second side 222 of the body 220. The lightning connector assembly 240 of this example includes a plurality of elongated connectors 250 distributed along the longitudinal direction 37 of the spar cap structure. The lightning connector assembly 240 may include between five and 30 elongated connectors 250. In some examples, each elongated connector 250 is associated with a lightning receiver (not shown in the figure). The elongated connectors 250 may protrude from one side of the body 220. In this example, the elongated connector 250 protrudes from the second side 222 of the body 220.

[0091] In this example, the elongated connector 250 extends in height between its outer end 241 and inner end 242. In this example, the height of the elongated connector 250 is greater than the thickness of the body 220. The elongated connector in this example protrudes from the body 220 and extends in a direction substantially parallel to the waving direction 39. This simplifies the connection of the lightning receiver to the outer end 241 of the elongated connector 250, and the connection of the inner end 242 to the downlead conductor via cable 420.

[0092] In some examples, foam material may be disposed between two consecutive elongated connectors 250. Thus, the foam material can fill the gap between the two elongated connectors 250. In other examples, fibers (e.g., carbon fiber and / or glass fiber) may be disposed between the elongated connectors 250.

[0093] In this example, multiple elongated connectors 250 include tubular shapes, such as cylindrical shapes. The elongated connectors 250 may include copper. The elongated connectors 250 may be hollow. This shape allows for good performance in terms of cost-effectiveness and conductivity. In other examples, the elongated connectors 250 may be solid, such as tubular solid elongated connectors. The tubular shape further enhances the connection between the conductive component 280 and the elongated connectors 250.

[0094] The metal conductive assembly 280 in this example is a metal conductive assembly. In this figure, the metal conductive assembly includes a plurality of conductive elements 290 distributed along the longitudinal direction 37. In this example, a group of conductive elements 290 are connected to each of the elongated connectors 250. Each group of conductive elements 290 is arranged at different heights relative to the thickness of the body. The conductive elements 290 in this example extend from a first end 291 to a second end 292 in a direction substantially perpendicular to the chordal direction 38. The second ends 292 of these conductive elements 290 are arranged at, for example, embedded within, conductive yarn 232. The conductive elements 290 in this example may be made of metal, such as copper.

[0095] In this example, the first end 291 of these conductive elements 290 is connected to the elongated connector 250. The first end 291 in this example includes a ring that inserts into the elongated connector 250. Therefore, the ring can easily establish an electrical connection between each conductive element 290 and the elongated connector 250.

[0096] Figure 6A and Figure 6B Examples of a portion of a spar cap structure according to this disclosure are schematically presented. These examples of spar cap structures include a plurality of carbon fiber pultruded members 231 arranged in rows. Conductive yarns 232 are arranged between the rows of carbon fiber pultruded members 231. In other examples, the body may be formed by laying a plurality of carbon fiber fabrics arranged in one layer on top of another.

[0097] It should be noted that these figures only show a portion of the spar cap structure. For example, the spar cap structure may further include a carbon fiber pultruded component 231 and a conductive yarn 232.

[0098] These exemplary conductive elements 290 include a second end 292 embedded within a conductive yarn 232. These exemplary conductive elements 290 include multiple metal conductive wires, such as copper wires, arranged in strands. Each of these strands of metal conductive wires is arranged at a different conductive yarn 232. In these examples, the second end 292 of these strands of metal conductive wires is spread out to increase the conductive surface area.

[0099] The first end 291 of the conductive element 290 in these diagrams is connected to the elongated connector 250. Figure 6AIn this configuration, the first end 291 of the conductive element 290 (e.g., a metal conductive element) is wound around the elongated connector 250. Figure 6B In this structure, each of the first ends 291 of the conductive elements 290 includes a conductive ring 295. The conductive ring 295 can be inserted into the elongated connector 250. Therefore, the assembly of the spar cap structure can be simplified.

[0100] Figure 7A and Figure 7B Examples of conductive elements according to this disclosure are schematically illustrated. The conductive element 290 in these figures extends from a first end 291 to a second end 292. In these examples, each of the first ends 291 includes a conductive loop 295. In other examples, the first end 291 may be wound around an elongated connector 250. The conductive element 290 may be a metallic conductive element according to any example in the examples herein.

[0101] In these examples, each of the second ends 292 is embedded within the conductive yarn 232. Figure 7A The conductive element 290 is a metal conductive element comprising multiple metal conductive wires 293 made of copper. The second end 292 of the metal conductive wires 293 is extended. The first end 291 of the metal conductive wires passes through and is connected to the conductive ring 295.

[0102] Figure 7B The conductive element 290 is a metallic conductive element that includes a metallic conductive membrane 294. The metallic conductive membrane is disposed within the conductive yarn 232. The metallic conductive element 290 in these figures can be arranged at any location according to the examples herein.

[0103] Figure 8A and Figure 8B Examples of isometric views of a portion of the spar cap structure according to this disclosure are schematically presented. The body 220 of these examples is... Figure 5 The subject shown is similar. In other examples, subject 220 may be based on any of the examples in this document.

[0104] These examples of lightning connector assemblies 240 include a plurality of strip connectors 260 extending along a longitudinal direction 37. Therefore, the lightning connector assembly 240 may include a plurality of strip connectors 260 distributed along a longitudinal direction 37. In these examples, a gap is defined between two consecutive strip connectors 260. Each strip connector 260 may be associated with a lightning receiver and with a cable 420 to connect the lightning receiver to a down conductor. In some examples, the gap may be filled with foam or fiber. In other examples, the gap may be left empty. In other examples, a body 220 extends a body length along a longitudinal direction 37, and the strip connectors 260 extend a strip length along a longitudinal direction 37. The strip length may substantially correspond to the body length. In other examples, the body length may be greater than the strip length.

[0105] As can be seen in these figures, the length of the strip connector 260 is variable. In these examples, the length of the strip connector 260 is longer than both its height and its width.

[0106] exist Figure 8A In this embodiment, the second end 292 of the conductive element 290 may be based on any example disclosed herein. For example, Figure 8A The second end 292 can be based on the information regarding Figure 5 The second end 292. However, the first end 291 of the conductive element 290 is wound around the strip connector 260. Therefore, each of the conductive elements 290 is electrically connectable to the corresponding strip connector 260. Therefore, the first end 291 of the conductive element 290 may include a bent portion. Figure 8A In the example, the curved portion at least partially surrounds the strip connector 260.

[0107] Figure 8B The first end 291 of the conductive element 290 is integrally incorporated into the corresponding conductive yarn 232. A portion of the conductive yarn 232 is wound around the strip connector 260. The conductive yarn 232 in this figure protrudes from the body 220 in the chordal direction 38. The conductive yarn 232 in this example may comprise a carbon biaxial fabric. The conductive element 290 may be a carbon fiber or metal conductive element 290, such as copper mesh and / or metal wire. Therefore, the conductive element 290 may be integrally incorporated into the carbon biaxial fabric. The first end 291 of the conductive element (e.g., a carbon fiber or metal conductive element) within the conductive yarn 232 may include a curved portion surrounding the strip connector 260. The length of the conductive yarn 232 may correspond to the length of the strip connector 260.

[0108] In other examples, conductive copper mesh may protrude from conductive yarn 232 to wrap around the strip connector.

[0109] In another example, the curved portion may extend along the gap formed between the side of the body 220 and the strip connector 260. Thus, the curved portion may at least partially cover a portion of one of the sides of the body to extend between the side and the strip connector 260.

[0110] Figure 9 This is a block diagram of a method for manufacturing a spar cap structure according to an example of this disclosure. Method 500 can be used to manufacture spar cap structures 110, 210 according to any example in the examples herein.

[0111] As shown in frame 510, method 500 includes forming a body 220 by stacking one or more layers of carbon fiber members to define a thickness between a first side 221 and a second side 222 of the body 220.

[0112] In some examples, carbon fiber fabric can be laid on the spar cap mold to form the body 220. In other examples, multiple carbon fiber pultruded parts 231 can be arranged on the spar cap mold to form rows of carbon fiber pultruded parts 231. Conductor yarn 232 can be arranged between two consecutive rows of carbon fiber pultruded parts 231.

[0113] As shown in frame 520, method 500 further includes arranging a lightning connector assembly 240 on one of the sides 221, 222 of the body 220, wherein the lightning connector assembly 240 extends in height from an outer end 241 to an inner end 242 in a direction substantially parallel to the thickness of the body 220. The outer end 241 is configured to connect to a lightning receiver, and the inner end 242 is configured to connect to a down conductor of a lightning protection system for a wind turbine blade. The lightning connector assembly 240 may be arranged near one of the first side 221 and the second side 222 of the body 220.

[0114] In some examples, arranging the lightning connector assembly 240 on one side 221, 222 of the body 220 includes arranging one or more strip connectors 260 along the longitudinal direction 37. In other examples, arranging the lightning connector assembly on one side 221, 222 of the body 220 includes arranging a plurality of elongated connectors distributed along the longitudinal direction 37.

[0115] Furthermore, as shown in box 530, method 500 includes arranging a conductive assembly 280 (e.g., a metal conductive assembly) from body 220 to lightning connector assembly 240 for electrically connecting body 220 to lightning connector assembly 240. In some examples, arranging the conductive assembly 280 includes contacting a first end 291 of one or more conductive elements 290 with lightning connector assembly 240 and a second end 292 of conductive elements 290 with body 220. Conductive elements 290 may be metal conductive elements or carbon fiber conductive elements.

[0116] In some examples, the second end 292 of the conductive element 290 may be connected to a carbon fiber component of the body 220, for example, embedded within a carbon fiber fabric. The second end 292 of the conductive element 290 may be laid during or after the placement of the carbon fiber fabric.

[0117] In some examples, a second end 292 of the conductive element 290 may be electrically connected to the conductive yarn 232. For example, the second end 292 may be placed on the conductive yarn 232. In other examples, the second end 292 may be positioned to be embedded within the conductive yarn 232. The second end 292 may be sewn to the fibers of the conductive yarn 232. In these examples, the method may include connecting the second end 292 of one or more conductive elements 290 to the conductive yarn 232, and arranging the conductive yarn 232 on a row of carbon fiber pultruded members 231. Then, another row of carbon fiber pultruded members 231 may be arranged on the conductive yarn 232. Additional conductive yarn 232 connected to the second end 292 of the additional conductive elements 290 is placed above this additional row of carbon fiber pultruded members 231. More rows of carbon fiber pultruded members 231 and conductive yarn 232 may be stacked to form a body 220.

[0118] In some examples, the first end 291 of the conductive element 290 includes a conductive ring 295. In some examples, arranging the conductive assembly 280 includes inserting the conductive ring 295 into the elongated connector 250.

[0119] In some examples, arranging the conductive assembly 280 includes wrapping the first end 291 around the elongated connector 250. In other examples, the first end 291 may be bent and positioned between the side of the main portion and the strip connector 260, or wrapped around the strip connector 260.

[0120] As shown in box 540, method 500 further includes bonding the lightning connector assembly 240 to the body 220. The body 220 and the lightning connector assembly 240 can be injection molded together. The conductive assembly 280 can also be injection molded together with the body 220 and the lightning connector assembly 240. Thus, resin can be injected into the spar cap mold to fill the gap between the layers forming the body 220 and the lightning connector assembly 240. The resin is then cured to form a prefabricated spar cap structure 110, 210. This can help automate the manufacturing process and simplify the arrangement of the stack on the outer layers. Thus, the spar cap structures 110, 210 can be prefabricated before being arranged on top of the outer layers 101, 201 placed on the blade mold. Furthermore, electrical connections can also be simplified. In other examples, the lightning connector assembly 240 can be attached to the injection-molded body 220 to form a prefabricated spar cap.

[0121] In another example, the body and lightning connector assembly 240 can be placed in the blade shell mold to be infused together with the blade shell.

[0122] Figure 10 This is a block diagram of a method for manufacturing a wind turbine blade according to one example of this disclosure. Method 600 can be used to manufacture wind turbine blades according to any example in the examples herein. These wind turbine blades include spar cap structures 110, 210 according to any example in the examples herein.

[0123] As shown at Figure 610, method 600 includes forming an upper blade shell portion 100 and a lower blade shell portion 200. Forming the upper blade shell portion 100 and the lower blade shell portion 200 includes arranging spar cap structures 110, 210 on an outer layer laid in a blade shell portion mold, and attaching the spar cap structures 110, 210 to the outer layer 201.

[0124] Method 600 may include laying outer layers 101, 201 in a blade shell mold, for example, laying one or more glass fiber laminates. These glass fiber laminates may include biaxially oriented glass fibers. Spallation cap structures 110, 210 may then be laid on the outer layers 101, 201.

[0125] As explained above, the wing cap structures 110 and 210 may be pre-assembled or prefabricated before being disposed on top of the outer layers 101 and 201. Alternatively, the wing cap may be formed on the outer layers 101 and 201. The wing cap structures may be manufactured according to any of the examples in this document.

[0126] The inner layers 102 and 202 can then be laid on top of the spar cap structures 110 and 210. The inner layers 102 and 202 may include one or more glass fiber laminates (e.g., having bidirectional glass fibers).

[0127] In some examples, one or more core structures may be placed near the spar cap structures 110, 210. The inner layer may be placed on top of these core structures.

[0128] The spar cap structures 110, 210 (prefabricated or directly disposed on top of the outer layer) can be bonded to the outer layers 101, 201 and to the inner layers 102, 202 to form the blade shell portions 100, 200. In some examples, bonding the spar cap structures 110, 210 to the outer layers 101, 201 and to the inner layers 102, 202 involves molding the inner layers, spar cap structures, and outer layers together using a resin infusion technique. Once the inner layer covers the spar cap structures and the outer layers, resin is injected into the mold cavity under pressure. This resin fills the space between the stack and the layers. The resin is then cured or hardened. Thus, the spar cap structure can be bonded to the inner layers and to the outer layers using a resin infusion process. After curing, the blade shell portions are obtained.

[0129] As shown in frame 620, method 600 further includes connecting the reinforcing structure 300 to the upper blade shell portion 100 and to the lower blade shell portion 200, such that the reinforcing structure 300 is arranged between the upper blade shell portion 100 and the lower blade shell portion 200. Therefore, the first reinforcing beam 310 can be connected to both the upper and lower blade shell portions. The lower flange 330 of the first reinforcing beam 310 can be connected to the lower blade shell portion 200, and the upper flange 320 of the first reinforcing beam 310 can be connected to the upper blade shell portion 100.

[0130] Connecting the flanges 320, 330 to the corresponding blade shell portions 100, 200 may include bonding or attaching the flanges 320, 330 to the corresponding inner layers 102, 202 of the blade shell portions 100, 200. Thus, an adhesive layer may be formed between the flanges 320, 330 and the inner layers 102, 202.

[0131] At frame 630, the upper blade shell portion 100 is connected to the lower blade shell portion 200. The blade shell portions are joined together by a bonding line formed at the leading edge 53 and the trailing edge 54.

[0132] In some examples, method 600 further includes inserting a plurality of lightning receivers into lightning connector assembly 240, for example, into the outer end 241 of lightning connector assembly 240. Lightning receivers 400 may be positioned at different locations along the spanwise direction 37 on the wind turbine blade. In some examples, lightning receivers 400 may be arranged at both the upper blade shell portion 100 and the lower blade shell portion 200.

[0133] In some examples, the inner end 242 of the lightning connector assembly 240 may be connected to the down conductor, for example, via a cable.

[0134] For the sake of completeness, various aspects of this disclosure are set forth in the following numbered clauses: Clause 1: A spar cap structure for a wind turbine blade, the spar cap structure comprising: The body includes a first side and a second side, wherein the body includes one or more layers of carbon fiber members, each of which is arranged as one layer on top of another to define the thickness of the body between the first side and the second side. A lightning connector assembly is disposed at one of the sides of the body, wherein the lightning assembly extends from an outer end to an inner end in a direction substantially parallel to the thickness of the body; wherein the outer end is configured to connect to a lightning receiver, and the inner end is configured to connect to a downconductor of a lightning protection system for a wind turbine blade; and A conductive component that extends from the body to the lightning connector assembly to electrically connect the body to the lightning connector assembly.

[0135] Clause 2: The spar cap according to Clause 1, wherein the lightning connector assembly includes a plurality of elongated connectors distributed along the longitudinal direction of the spar cap.

[0136] Clause 3: The spar cap according to Clause 1, wherein the lightning connector assembly includes a strip connector extending in the longitudinal direction of the spar cap.

[0137] Clause 4: The wing cap according to any one of Clauses 1 to 3 includes a conductive layer that at least partially surrounds the lightning connector assembly and the body.

[0138] Clause 5: A spar cap according to any one of Clauses 1 to 4, wherein the conductive assembly includes a conductive element comprising a first end connected to the lightning connector assembly and a second end connected to a layer of carbon fiber member.

[0139] Clause 6: The spar cap according to Clause 5, wherein the conductive assembly includes a plurality of conductive elements distributed along the longitudinal direction of the spar cap.

[0140] Clause 7: The spar cap according to Clause 6, wherein one or more carbon fiber components comprise a layer of carbon fiber fabric, and wherein a second end of the conductive element is embedded in the carbon fiber fabric layer.

[0141] Clause 8: A spar cap pursuant to any of Clauses 5 to 6, wherein each of the layers of one or more carbon fiber components comprises a row of one or more carbon fiber pultruded components.

[0142] Clause 9: The spar cap according to Clause 8, wherein the conductive assembly includes conductive elements distributed along the thickness of the body.

[0143] Clause 10: A spar cap according to any one of Clauses 8 to 9, wherein the body comprises conductive yarn arranged between two consecutive rows of carbon fiber pultruded material, and wherein a second end of the conductive element is embedded in the conductive yarn.

[0144] Clause 11: A spar cap according to any one of Clauses 5 to 10, wherein the conductive element comprises a multistrand of metal conductive wire, optionally copper wire.

[0145] Clause 12: A spar cap according to any one of Clauses 5 to 10, wherein the metal conductive element includes a metal conductive film, optionally a copper film.

[0146] Clause 13: A spar cap pursuant to any of Clauses 5 to 12, wherein the first end includes a conduction ring.

[0147] Clause 14: The spar cap according to Clause 13, wherein the connector assembly includes a plurality of elongated connectors distributed along the longitudinal direction of the spar cap, and wherein a conductive ring surrounds the arrangement of the elongated connectors.

[0148] Clause 15: A spar cap according to any one of Clauses 5 to 12, wherein the connector assembly includes a plurality of elongated connectors distributed along the longitudinal direction of the spar cap, and wherein a first end is wound around the elongated connectors.

[0149] Clause 16: A wing cap according to any one of Clauses 5 to 12, wherein the first end includes a curved portion to at least partially cover a portion of one of the sides of the body.

[0150] Clause 17: A wind turbine blade extending in a longitudinal direction, the wind turbine blade comprising: Upper blade shell portion; The lower blade shell portion is connected to the upper blade shell portion; The reinforcing structure between the upper blade shell and the lower blade shell; and The upper blade shell portion and / or lower blade shell portion include a spar cap structure according to any one of Clauses 1 to 16.

[0151] Clause 18: A method for manufacturing a spar cap structure, comprising: The body is formed by stacking one or more carbon fiber components in multiple layers to define the thickness between the first and second sides of the body.

[0152] A lightning connector assembly is arranged on one side of the body, wherein the lightning connector assembly extends from the outer end to the inner end in a direction substantially parallel to the thickness of the body; wherein the outer end is configured to connect to a lightning receiver, and the inner end is configured to connect to the down conductor of the lightning protection system of the wind turbine blade. The conductive components are arranged to extend from the body to the lightning connector assembly for electrically connecting the body to the lightning connector assembly, and Integrate the lightning connector assembly into the main body.

[0153] Clause 19: The method according to Clause 18, wherein combining the lightning connector assembly includes potting the lightning connector assembly together with the body.

[0154] Clause 20: A method for manufacturing a wind turbine blade according to Clause 17, comprising: Forming an upper blade shell portion and a lower blade shell portion, wherein forming the upper blade shell portion and / or the lower blade shell portion includes: The sparsity cap structure is arranged on the outer layer laid in the mold of the blade shell section; and Integrate the wing spar cap structure into the outer layer; The reinforcing structure is connected to both the upper and lower blade shell portions, such that the reinforcing structure is positioned between the upper and lower blade shell portions. Connect the upper blade shell to the lower blade shell.

[0155] This written description uses examples to disclose the invention, including preferred embodiments, and also enables any person skilled in the art to practice the invention, including making and using any device or system and performing any combined methods. The scope of the invention is defined by the claims and may include other examples that would occur to a person skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that are not different from the written language of the claims, or if they include equivalent structural elements that are not substantially different from the written language of the claims. Aspects from the various embodiments described, and other known equivalents of each such aspect, may be mixed and matched by a person skilled in the art to constitute additional embodiments and techniques according to the principles of this application. If reference marks related to figures are placed in brackets in the claims, they are only for attempting to increase the comprehensibility of the claims and should not be construed as limiting the scope of the claims.

Claims

1. A spar cap structure (110, 210) for a wind turbine blade (7), the spar cap structure (110, 210) comprising: A body (220) comprising a first side (221) and a second side (222), wherein the body (220) comprises one or more layers of carbon fiber members, each of which is arranged as one layer on top of another to define the thickness of the body (220) between the first side (221) and the second side (222); A lightning connector assembly (240) is disposed at one of the sides (221, 222) of the body (220), wherein the lightning connector assembly (240) extends in height from an outer end (241) to an inner end (242) in a direction substantially parallel to the thickness of the body (220); wherein the outer end (241) is configured to connect to a lightning receiver, and the inner end (242) is configured to connect to a down conductor of a lightning protection system for a wind turbine blade (7); as well as A conductive component (280) extends from the body (220) to the lightning connector assembly (240) to electrically connect the body (220) to the lightning connector assembly (240).

2. The wing spar cap structure (110, 210) according to claim 1, wherein, The lightning connector assembly (240) includes a plurality of elongated connectors (250) distributed along the longitudinal direction (37) of the spar cap structure (110, 210).

3. The wing spar cap structure (110, 210) according to claim 1, wherein, The lightning connector assembly (240) includes a strip connector (260) extending along the longitudinal direction (37) of the spar cap structure (110, 210).

4. The wing spar cap structure (110, 210) according to any one of claims 1 to 3, wherein, The conductive assembly (280) includes a conductive element (290) comprising a first end (291) connected to the lightning connector assembly (240) and a second end (292) connected to a layer of carbon fiber member.

5. The wing spar cap structure (110, 210) according to claim 4, wherein, The conductive assembly (280) includes a plurality of conductive elements (290) distributed along the longitudinal direction (37) of the spar cap structure (110, 210).

6. The wing spar cap structure (110, 210) according to claim 5, wherein, The layer of one or more carbon fiber components includes a carbon fiber fabric layer (235), and the second end (292) of the conductive element (290) is embedded in the carbon fiber fabric layer (235).

7. The wing spar cap structure (110, 210) according to any one of claims 4 to 5, wherein, Each of the layers of one or more carbon fiber components comprises rows of one or more carbon fiber pultrusions (231).

8. The wing spar cap structure (110, 210) according to claim 7, wherein, The conductive assembly (280) includes conductive elements (290) distributed along the thickness of the body (220).

9. The wing spar cap structure (110, 210) according to any one of claims 7 to 8, wherein, The body (220) includes a conductive yarn (232) arranged between two consecutive rows of carbon fiber pultruded material (231), and the second end (292) of the conductive element (290) is embedded in the conductive yarn (232).

10. The wing spar cap structure (110, 210) according to any one of claims 4 to 9, wherein, The conductive element (290) includes multiple strands of metal conductive wire (293), which may be copper wire.

11. The wing spar cap structure (110, 210) according to any one of claims 4 to 9, wherein, The conductive element (290) includes a metal conductive film (294), optionally a copper film.

12. The spar cap structure (110, 210) according to any one of claims 4 to 11, wherein, The first end (291) includes a conductive ring (295).

13. The spar cap structure (110, 210) according to any one of claims 4 to 11, wherein, The lightning connector assembly (240) includes a plurality of elongated connectors (250) distributed along the longitudinal direction (37) of the spar cap structure (110, 210), wherein the first end (291) is wound around the elongated connector (250).

14. A wind turbine blade (7) extending in a longitudinal direction (37), the wind turbine blade (7) comprising: Upper blade shell portion (100); The lower blade shell portion (200) is connected to the upper blade shell portion (100). The reinforcing structure (300) between the upper blade shell portion (100) and the lower blade shell (200); and The upper blade shell portion (100) and / or the lower blade shell portion (200) include a spar cap structure (110, 210) according to any one of claims 1 to 13.

15. A method (500) for manufacturing a spar cap structure (110, 210), comprising: (510) Body (220) is formed by stacking one or more carbon fiber components in multiple layers to define a thickness between a first side (221) and a second side (222) of the body (220); A lightning connector assembly (240) is arranged (520) on one of the sides (221, 222) of the body (220), wherein the lightning connector assembly (240) extends in height from an outer end (241) to an inner end (242) in a direction substantially parallel to the thickness of the body (220); wherein the outer end (241) is configured to connect to a lightning receiver, and the inner end (242) is configured to connect to a down conductor of a lightning protection system for a wind turbine blade (7); The conductive component (280) is arranged (530) to extend from the body (220) to the lightning connector assembly (240) for electrically connecting the body (220) to the lightning connector assembly (240), and The lightning connector assembly (240) is attached (540) to the body (220).

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