A wind turbine blade with a built-in continuous flexible metal mesh skeleton and a manufacturing method

Abstract

The application relates to the technical field of wind turbines, and discloses a wind turbine blade with a built-in continuous flexible metal mesh framework and a manufacturing method, which comprises a flexible continuous metal mesh framework which is a three-dimensional network structure and is adapted to the shape of the wind turbine blade; and a composite material layer which is arranged on the outside of the flexible continuous metal mesh framework. The flexible continuous metal mesh framework is used as an internal support structure, the toughness and fatigue resistance of the three-dimensional network structure are utilized to absorb and disperse stress, thereby the crack propagation can be inhibited, the fatigue resistance and structural durability of the blade are significantly improved; the composite material layer is arranged on the outside of the flexible continuous metal mesh framework, even if the composite material layer is locally damaged or cracked, the integrity of the basic structure of the wind turbine blade can be maintained by the ductility of the flexible continuous metal mesh framework, catastrophic fracture is avoided, a gradual failure mode is provided, the damage tolerance is improved, and sufficient reliability is achieved under long-term operation conditions.

Description

Technical Field

[0001] This invention relates to the field of wind turbine technology, and in particular to a wind turbine blade with a built-in continuous flexible metal mesh frame and its manufacturing method. Background Technology

[0002] Wind turbine blades have evolved from wood and steel to aluminum alloys, and now to the dominant fiber-reinforced composite materials. Currently, wind turbine blades primarily improve strength by increasing the thickness of the composite material or changing the layup design. However, this often leads to increased blade weight and manufacturing costs, and fails to effectively address fatigue issues. To overcome the performance bottlenecks of rigid blades, flexible blades have been gradually developed and applied to wind turbines. Their core purpose is to give the blades a certain degree of deformability, allowing them to actively or passively change their aerodynamic shape (such as camber and torsion angle) according to different wind conditions or operating states. This maintains optimal energy capture efficiency across a wider range of operating conditions and reduces extreme loads.

[0003] Existing flexible blades include purely composite material flexible blades and flexible blades with internally embedded reinforcing structures. Purely composite material flexible blades, by designing the layup sequence, angle, and thickness of the composite material, utilize the anisotropic mechanical properties of the composite material to create different stiffnesses in different regions of the blade, thereby achieving predetermined bending and torsional deformations. However, they have the following technical drawbacks: 1. Insufficient fatigue resistance and damage tolerance: The brittleness of the composite matrix makes it prone to microcrack initiation under cyclic loading, and once formed, the cracks propagate rapidly, leading to a sharp decline in structural strength and ultimately brittle fracture. This failure mode is sudden and lacks early warning.

[0004] 2. High manufacturing cost and difficulty in process control: Precise control of the flexible deformation of the blade requires extremely complex layup design and high-quality manufacturing process, which makes the blade cost high and makes it difficult to guarantee the consistency of quality.

[0005] 3. Stress concentration caused by anisotropy: The mechanical properties of fiber-reinforced composites differ greatly in the fiber direction and perpendicular to the fiber direction. This makes it easy for interlaminar shear stress concentration to occur in regions with complex geometry or variable load directions, which can become the starting point for structural failure.

[0006] Flexible blades with internally embedded reinforcing structures (such as stiffeners or beams) can provide necessary structural support while maintaining flexibility. However, such flexible blades have the following technical drawbacks: 1. Uneven load transfer and stress concentration: Discrete reinforcement structures cause loads to be primarily transferred along these reinforcement structures. Significant stress concentration problems exist at the ends, intersections, or connections with the skin of the reinforcement structures.

[0007] 2. Inadequate flexible control: The reinforced structure restricts the deformation of the surrounding area, making the overall flexible deformation of the blade less smooth and continuous, which may have an adverse effect on aerodynamic performance.

[0008] In view of this, how to partially or completely overcome the technical defects of the aforementioned flexible blades is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0009] The purpose of this invention is to provide a wind turbine blade with a built-in continuous flexible metal mesh skeleton and a manufacturing method thereof, so as to solve the problems existing in the prior art.

[0010] To achieve the above objectives, this invention provides an integrated composite structure with an internal independently formed flexible continuous metal mesh skeleton and an external composite material layer, as well as a method for manufacturing the same, to systematically overcome the aforementioned technical defects, thereby obtaining a novel flexible blade that combines excellent aerodynamic performance, superior structural reliability, high damage tolerance, relatively simplified manufacturing costs, and long service life.

[0011] Specifically, a wind turbine blade with a built-in continuous flexible metal mesh frame includes: The flexible continuous metal mesh skeleton is a three-dimensional network structure that is adapted to the shape of wind turbine blades. A composite material layer is applied to the outside of the flexible continuous metal mesh skeleton.

[0012] Furthermore, the flexible continuous metal mesh skeleton includes an integrally connected upper skeleton layer and a lower skeleton layer, with the upper skeleton layer and the lower skeleton layer forming a blade cavity.

[0013] Furthermore, one or more webs are provided within the cavity, with the upper end of the webs connected to the upper skeleton layer and the lower end connected to the lower skeleton layer.

[0014] Furthermore, the flexible continuous metal mesh skeleton is composed of metal wires connected together, with adjacent metal wires connected by welding, weaving or 3D printing, and the outer diameter of the metal wires is 0.5mm-3.0mm.

[0015] Furthermore, wind turbine blades have high-stress and low-stress zones, and the outer diameter of the metal wire in the high-stress zone is larger than that in the low-stress zone.

[0016] Furthermore, the arrangement density of metal wires in the high-stress zone is higher than that in the low-stress zone.

[0017] Furthermore, the three-dimensional network of the flexible continuous metal mesh skeleton adopts square, hexagonal, rhomboid or mixed gradient three-dimensional mesh holes.

[0018] Furthermore, the flexible continuous metal mesh skeleton is made of one or more of stainless steel, high carbon steel, titanium alloy, and nickel-chromium alloy.

[0019] Furthermore, the composite material layer is composed of reinforcing fibers and matrix resin. The reinforcing fibers are E-glass fibers, S-glass fibers, or carbon fibers, and the fiber form is non-woven fabric, felt, woven fabric, or multi-axial fabric. The matrix resin is epoxy resin, vinyl ester resin, or unsaturated polyester resin.

[0020] This invention also provides a method for manufacturing a wind turbine blade with an internal continuous flexible metal mesh skeleton, comprising the following steps: S1: Make an upper mold and a lower mold to match the shape of the wind turbine blade. The upper mold and the lower mold form a mold cavity that fits the shape of the wind turbine blade. Coat the inner surface of the upper mold and the lower mold with a release agent. S2: Place the flexible continuous metal mesh skeleton into the lower mold, and limit the flexible continuous metal mesh skeleton by tooling or pads, so that there is a gap between the flexible continuous metal mesh skeleton and the inner surface of the mold cavity. S3: Lay fiber fabric on the outer surface of the flexible continuous metal mesh skeleton; S4: Close the upper mold and the lower mold together and seal them with a vacuum bag. The upper mold and / or the lower mold have a vacuum port and a resin injection port. First, use a vacuum pump to evacuate the mold cavity through the vacuum port. After the preset vacuum level is reached, open the valve of the resin injection port and use negative pressure to inject liquid resin into the mold cavity to impregnate the fiber fabric and completely wrap the flexible continuous metal mesh skeleton. S5: After the liquid resin has completely filled the mold cavity, close the valve of the resin injection port. After the liquid resin has solidified, a composite material layer is formed. S6: Demolding yields wind turbine blades.

[0021] The present invention discloses the following technical effects: 1. This invention uses a flexible continuous metal mesh skeleton as the internal support structure, and utilizes the toughness and fatigue resistance of the three-dimensional network structure to absorb and disperse stress, thereby inhibiting crack propagation and significantly improving the fatigue resistance and structural durability of the blade. In addition, this invention arranges a composite material layer on the outside of the flexible continuous metal mesh skeleton. Even if the composite material layer suffers local damage or cracking, the integrity of the basic structure of the wind turbine blade can be maintained by the ductility of the flexible continuous metal mesh skeleton, avoiding catastrophic fracture. This provides a progressive failure mode, improves damage tolerance, and has sufficient reliability under long-term operating conditions.

[0022] 2. This invention uses vacuum injection to manufacture wind turbine blades, which has lower manufacturing costs and reduced process control difficulty compared with existing technologies, enabling mass production and ensuring product quality.

[0023] 3. By adjusting the outer diameter and arrangement density of the metal wires, this invention can precisely control the overall stiffness distribution of the wind turbine blade, enabling it to produce smooth, continuous, and aerodynamically optimized flexible deformation under aerodynamic loads. The flexible continuous metal mesh skeleton evenly distributes local loads throughout the entire blade structure, avoiding stress concentration.

[0024] 4. The flexible continuous metal mesh skeleton is made of metal materials. After the blades have finished their service, they can be physically separated from the composite material layer, thus enabling efficient recycling and reuse of the flexible continuous metal mesh skeleton. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of a flexible continuous metal mesh skeleton structure. Figure 2 This is a schematic diagram showing the combination of the composite material layer and the flexible continuous metal mesh skeleton. Figure 3 A schematic diagram of a flexible continuous metal mesh skeleton structure with cavities; Figure 4 A schematic diagram of a flexible continuous metal mesh skeleton structure with webs arranged in a cavity; Among them, 1. Flexible continuous metal mesh skeleton; 2. Composite material layer; 3. Web plate. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] Those skilled in the art will understand that the term "comprising" as used in this application means the presence of the stated features, integers, steps, operations, elements, and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. It should be understood that when we say an element is "connected" or "coupled" to another element, it can be directly connected or coupled to the other element, or there may be intermediate elements present. Furthermore, "connected" or "coupled" as used herein can include wireless connections or wireless coupling. The term "and / or" as used herein includes all or any unit and all combinations of one or more associated listed items.

[0029] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0030] Example 1 This invention provides a wind turbine blade with a built-in continuous flexible metal mesh frame, comprising: The flexible continuous metal mesh skeleton 1 is a three-dimensional network structure that is adapted to the shape of the wind turbine blade; Composite material layer 2 covers the outside of flexible continuous metal mesh skeleton 1.

[0031] Figure 1 The diagram shows the three-dimensional morphology and three-dimensional network distribution of the flexible continuous metal mesh skeleton 1 used in this embodiment. Its overall structure is similar to the shape of a wind turbine blade, with streamlined transition structures at both ends. The flexible continuous metal mesh skeleton 1 is woven from metal wires (steel wires) without any cavities in the middle. It can be divided into an inner layer, a middle layer, and an outer layer. The density of the metal wires in each layer can be the same or different. Its three-dimensional network adopts a square shape, which not only ensures structural strength but also facilitates the subsequent coating of the composite material layer 2.

[0032] In other embodiments, the metal wire can also be made of one or more of stainless steel, high-carbon steel, titanium alloy, and nickel-chromium alloy. All of these metal materials possess high strength, high toughness, and excellent fatigue resistance. Shape memory alloys can also be used; this flexible continuous metal mesh skeleton 1 made of shape memory alloy can recover to a preset shape at a specific temperature. By integrating tiny heating elements inside the blade, active deformation of the blade shape can be achieved, shifting from passive adaptation to active control to cope with more complex operating conditions.

[0033] In other embodiments, the flexible continuous metal mesh skeleton 1 can also be replaced with a mesh skeleton woven from high-strength, high-modulus polymer fibers (such as aramid fibers or ultra-high molecular weight polyethylene fibers). The advantages are extremely light weight and excellent corrosion resistance. This can further achieve blade lightweighting, but the cost may be higher, and its interfacial bonding with the matrix resin requires special treatment.

[0034] In other embodiments, the flexible continuous metal mesh skeleton 1 can also be replaced by a mesh skeleton made of pultruded composite material ribs (such as carbon fiber or glass fiber ribs) through weaving or bonding. This skeleton has the advantages of being lightweight and high-strength, and its material system is consistent with that of the outer composite material layer 2, resulting in good interfacial compatibility.

[0035] In this embodiment, the surface of the metal wire may be treated with anti-corrosion measures (such as zinc plating, aluminizing, or polymer coating) to enhance its durability in harsh environments.

[0036] In other embodiments, adjacent wires can be welded or 3D printed together, with the outer diameter of the wires ranging from 0.5mm to 3.0mm. For the connection method between the wires, welding and 3D printing methods result in nodes with high rigidity and good overall integrity; while weaving allows for minute rotations between nodes, offering better flexibility.

[0037] In other embodiments, the flexible continuous metal mesh skeleton 1 can also be formed into a porous or mesh structure using a thin metal plate that has been stamped or laser-cut. Alternatively, it can be a skeleton composed of multiple bundles of metal wires arranged along a specific trajectory (such as a spiral or geodesic).

[0038] In other embodiments, the flexible continuous metal mesh skeleton 1 can also arrange continuous metal wire bundles or carbon fiber bundles in the main load-bearing direction of the blade (such as the spanwise direction), while using finer metal mesh to connect them in other directions, forming a hybrid reinforcement structure of main ribs + mesh.

[0039] In this embodiment, the structural parameters of the flexible continuous metal mesh skeleton 1 are key to achieving controllable flexibility and can be optimized according to the stress conditions of different regions of the wind turbine blade. Wind turbine blades have high-stress and low-stress areas. For example, the connection between the horizontal axis blade and the hub, and the connection between the vertical axis wind turbine blade and the support arm, as well as the leading edge, are typical stress concentration areas, belonging to high-stress areas, and bearing the greatest bending moment, shear force, and dynamic impact. The outer diameter of the metal wire corresponding to the high-stress area is larger than that of the metal wire corresponding to the low-stress area. For example, the outer diameter of the metal wire can be gradually increased by 0.3-0.8 mm to achieve a smooth transition in stiffness and avoid stress concentration caused by sudden changes in local stiffness.

[0040] In this embodiment, the arrangement density of the metal wires corresponding to the high stress region is higher than that of the metal wires corresponding to the low stress region.

[0041] In this embodiment, the three-dimensional network of the flexible continuous metal mesh skeleton 1 adopts square, hexagonal, rhomboid, or mixed gradient three-dimensional mesh openings to avoid a single orthogonal structure. After the metal wires in the high-stress area are densely arranged, the size of the three-dimensional mesh openings is also reduced, which enhances the load distribution capability. The sparse arrangement of metal wires in the low-stress area helps to reduce weight and increase deformation capacity. The flexible continuous metal mesh skeleton 1 has multiple functions in wind turbine blades: (a) Main load-bearing structure, bearing the main tensile, compressive, shear and torsional loads; (b) Toughness reinforcement, suppressing the propagation of microcracks in composite layer 2; (c) Stiffness controller, determining the overall flexible deformation mode of the blade through the distribution of its own parameters; (d) Shape stabilizer, ensuring that the blade can reliably return to its original shape after deformation.

[0042] In this embodiment, the composite material layer 2 is composed of reinforcing fibers and a matrix resin. The reinforcing fibers are E-glass fibers, S-glass fibers, or carbon fibers, and the fiber form is non-woven fabric, felt, woven fabric, or multi-axial fabric. Among them, E-glass fibers have lower cost, S-glass fibers have higher strength, and carbon fibers have the best performance but are more expensive. The matrix resin is epoxy resin, vinyl ester resin, or unsaturated polyester resin. Among them, epoxy resin has good overall performance, vinyl ester resin has good corrosion resistance, and unsaturated polyester resin has low cost. The selection of the matrix resin needs to consider its adhesion performance with the flexible continuous metal mesh skeleton 1 and its toughness after curing. The composite material layer 2 has multiple functions in the wind turbine blade: (a) Forming a precise aerodynamic shape to ensure excellent aerodynamic performance of the blade; (b) Protecting the internal flexible continuous metal mesh skeleton 1 from environmental erosion (moisture, ultraviolet rays, chemicals, etc.); (c) Transmitting aerodynamic pressure by uniformly transferring the force acting on the blade surface to the internal flexible continuous metal mesh skeleton 1; (d) Providing local stiffness, especially in terms of the skin's dent resistance.

[0043] In other embodiments, the composite material layer 2 can also be replaced by the following alternatives: 1. Thermoplastic composite materials: Thermoplastic resins (such as polypropylene (PP) and polyamide (PA) and their fiber-reinforced composites are used as the outer materials. Advantages include better toughness, recyclability, and a shorter processing cycle (no chemical curing required). During manufacturing, the adhesive properties of the flexible continuous metal mesh skeleton 1 and its post-curing toughness can be incorporated into a mold, and then injection molded or compression molded.

[0044] 2. Introduction of lightweight core material: Lightweight foam core material (such as PVC or PET foam) or honeycomb material can be filled into the mesh voids of the flexible continuous metal mesh skeleton 1, which exhibits good adhesion and toughness after curing, forming a skeleton-core-skin sandwich structure. This can significantly improve the bending strength and stability of the blades without significantly increasing weight.

[0045] 3. Casting and Molding: For small blades, the flexible continuous metal mesh skeleton 1 can be directly placed in a mold, and then a liquid polymer (such as polyurethane elastomer) filled with chopped fibers or nanofillers can be poured in and cured to form the desired shape. This process is simpler and faster.

[0046] This invention also provides a method for manufacturing a wind turbine blade with an internal continuous flexible metal mesh skeleton, comprising the following steps: S1: Make an upper mold and a lower mold to match the shape of the wind turbine blade. The upper mold and the lower mold form a mold cavity that fits the shape of the wind turbine blade. Coat the inner surface of the upper mold and the lower mold with a release agent. S2: Place the flexible continuous metal mesh skeleton 1 into the lower mold, and limit the flexible continuous metal mesh skeleton 1 by tooling or pads, so that there is a gap between the flexible continuous metal mesh skeleton 1 and the inner surface of the mold cavity. S3: Lay fiber fabric on the outer surface of the flexible continuous metal mesh skeleton 1; S4: Close the upper mold and the lower mold together and seal them with a vacuum bag. The upper mold and / or the lower mold have a vacuum port and a resin injection port. First, use a vacuum pump to evacuate the mold cavity through the vacuum port. After the preset vacuum level is reached, open the valve of the resin injection port and use negative pressure to inject liquid resin into the mold cavity to impregnate the fiber fabric and completely wrap the flexible continuous metal mesh skeleton 1. Figure 2The figure shows the three-dimensional shape of the flexible continuous metal mesh skeleton 1 covered by the composite material layer 2 (part of the composite material layer 2 is not shown in order to show the flexible continuous metal mesh skeleton 1). The resin injection port is located in the middle of the flexible continuous metal mesh skeleton 1. The liquid resin gradually wraps the flexible continuous metal mesh skeleton 1 from the middle to both ends. The coating thickness is uniform and it is closely attached to the surface of the metal mesh skeleton. S5: After the liquid resin has completely filled the mold cavity, close the valve of the resin injection port. After the liquid resin has solidified, it forms the composite material layer 2. S6: Demolding yields wind turbine blades.

[0047] Explanation of the working principle of this embodiment: When wind acts on the blade surface, it generates uneven aerodynamic pressure. This pressure is first borne by the outer composite material layer 2 and then rapidly transferred through the matrix resin to the inner flexible continuous metal mesh skeleton 1. Because the flexible continuous metal mesh skeleton 1 is a continuous three-dimensional structure, the load is rapidly distributed to the entire blade along numerous paths, avoiding excessive concentration of local stress.

[0048] Under load, the blades undergo elastic deformation. The pattern and magnitude of this deformation are dominated by the preset stiffness distribution of the flexible continuous metal mesh framework 1. For example, when the blades rotate to the windward side, the aerodynamic load is at its maximum, and the blades may experience slight backward bending and torsion. This passive deformation can moderately reduce the local angle of attack, delay stall, and may provide unloading protection at high wind speeds. When the blades rotate to a smaller angle of attack, the load decreases, and the blades recover to their original shape using their own elastic restoring force (mainly provided by the flexible continuous metal mesh framework 1).

[0049] The entire process is passively adaptive, requiring no active control system. This flexible deformation not only helps optimize aerodynamic performance across a wide range of wind speeds and angles of attack, but also dissipates vibrational energy through the damping effect of the structure itself, improving operational stability.

[0050] Example 2 like Figure 3 As shown, the difference between this embodiment and Embodiment 1 is that the flexible continuous metal mesh skeleton 1 includes an integrally connected upper skeleton layer and a lower skeleton layer, and the upper skeleton layer and the lower skeleton layer form a blade cavity.

[0051] This structural form can be defined as a single-layer flexible continuous metal mesh. In other embodiments, double-layer, triple-layer, or multi-layer flexible continuous metal meshes can also be used, with blade cavities in the middle.

[0052] Example 3 like Figure 4As shown, the difference between this embodiment and embodiment 2 is that one or more web plates 3 are provided in the cavity, the upper end of the web plate 3 is connected to the upper skeleton layer, and the lower end is connected to the lower skeleton layer.

[0053] Example 2 is mainly applied to small wind turbine blades, while Example 3 is mainly applied to large wind turbine blades. The purpose of adding the web 3 is to avoid excessive deformation and improve the overall stiffness.

[0054] In this embodiment, the web 3 can be made of lightweight, high-strength materials, such as pultruded glass fiber or carbon fiber I-beams or box girders, or it can be a hollow metal profile. The web 3 and the flexible continuous metal mesh skeleton 1 are pre-integrated into a complete skeleton before the composite material layer 2 is cast. The integration method can be by gluing or lay-up the web 3 and the flexible continuous metal mesh skeleton 1, and the flexible continuous metal mesh skeleton 1 is firmly connected to these connection points by mechanical fasteners, welding, or high-strength structural adhesives. This integration ensures that the rigid support of the web 3 can be effectively transferred to the entire blade, while the flexible characteristics of the flexible continuous metal mesh skeleton 1 are still preserved.

[0055] Stress tests were performed on Example 2, and the results showed that: The peak stress corresponding to Example 2 is 400 MPa (the peak stress of a conventional wind turbine blade is around 850 MPa), while the peak stress of Example 1 is 280-320 MPa. After halving the three-dimensional mesh size in Example 1, the peak stress drops to below 200 MPa. The peak stresses of Examples 1-3 are all far below the yield strength of the metal wire, thereby significantly improving the safety margin and fatigue life of the wind turbine blade.

[0056] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0057] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0058] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0059] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A wind turbine blade with a built-in continuous flexible metal mesh frame, characterized in that, include: The flexible continuous metal mesh skeleton (1) is a three-dimensional network structure that is adapted to the shape of the wind turbine blade; A composite material layer (2) is provided on the outside of the flexible continuous metal mesh skeleton (1); The flexible continuous metal mesh skeleton (1) includes an integrally connected upper skeleton layer and a lower skeleton layer, and the upper skeleton layer and the lower skeleton layer form a blade cavity. One or more web plates (3) are provided in the cavity. The upper end of the web plate (3) is connected to the upper skeleton layer and the lower end is connected to the lower skeleton layer. The flexible continuous metal mesh skeleton (1) is composed of metal wires connected together. Adjacent metal wires are connected by welding, weaving or 3D printing. The outer diameter of the metal wires is 0.5mm-3.0mm. Wind turbine blades have high-stress and low-stress areas, and the outer diameter of the metal wire in the high-stress area is larger than the outer diameter of the metal wire in the low-stress area. The arrangement density of metal wires in the high-stress zone is higher than that in the low-stress zone.

2. The wind turbine blade with a built-in continuous flexible metal mesh frame according to claim 1, characterized in that, The three-dimensional network of the flexible continuous metal mesh skeleton (1) adopts square, hexagonal, rhomboid or mixed gradient three-dimensional mesh holes.

3. A wind turbine blade with a built-in continuous flexible metal mesh frame according to claim 1, characterized in that, The flexible continuous metal mesh skeleton (1) is made of one or more of stainless steel, high carbon steel, titanium alloy, and nickel-chromium alloy.

4. A wind turbine blade with a built-in continuous flexible metal mesh frame according to claim 1, characterized in that, The composite material layer (2) is composed of reinforcing fibers and matrix resin. The reinforcing fibers are E-glass fibers, S-glass fibers or carbon fibers, and the fiber form is non-woven fabric, felt, woven fabric or multi-axial fabric. The matrix resin is epoxy resin, vinyl ester resin or unsaturated polyester resin.

5. A method for manufacturing a wind turbine blade with a built-in continuous flexible metal mesh skeleton, characterized in that, The method for manufacturing a wind turbine blade with a built-in continuous flexible metal mesh frame as described in any one of claims 1-4 includes the following steps: S1: Make an upper mold and a lower mold to match the shape of the wind turbine blade. The upper mold and the lower mold form a mold cavity that fits the shape of the wind turbine blade. Coat the inner surface of the upper mold and the lower mold with a release agent. S2: Place the flexible continuous metal mesh skeleton (1) into the lower mold, and limit the flexible continuous metal mesh skeleton (1) by tooling or pads, so that there is a gap between the flexible continuous metal mesh skeleton (1) and the inner surface of the mold cavity. S3: Fiber fabric is laid on the outer surface of the flexible continuous metal mesh skeleton (1); S4: Close the upper mold and the lower mold together and seal them with a vacuum bag. The upper mold and / or the lower mold have a vacuum port and a resin injection port. First, use a vacuum pump to evacuate the mold cavity from the vacuum port. After the preset vacuum level is reached, open the valve of the resin injection port and use negative pressure to inject liquid resin into the mold cavity to impregnate the fiber fabric and completely wrap the flexible continuous metal mesh skeleton (1). S5: After the liquid resin has completely filled the mold cavity, close the valve of the resin injection port. After the liquid resin has solidified, a composite material layer is formed (2). S6: Demolding yields wind turbine blades.

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