Wind turbine blade component

Abstract

There is provided a wind turbine blade component for a wind turbine blade. The wind turbine component comprises a main body and a first guide. The main body comprises a plurality of layers, including a first layer and a second layer, the layers being arranged one on top of the other between a first side and a second side thereof, whereby the main body spans a thickness. The layers comprise fiber pultrusions. The first guide, which comprises a porous material, is arranged at the first side of the main body. The first guide comprises a plurality of portions, including a first portion and a second portion, the portions being arranged one on top of the other. Each of the plurality of portions of the first guide is associated with one or more layers of the plurality of layers. A width of the first portion of the first guide is different to a width of the second portion of the first guide, whereby a plane in which the first layer abuts the first portion of the first guide is misaligned with a plane in which the second layer abuts the second portion of the first guide.

Description

[0001] Wind Turbine Blade Component

[0002] The present disclosure relates to a wind turbine blade component comprising a main body and a first guide, a method of manufacturing the wind turbine blade component and a method of manufacturing a wind turbine blade including the wind turbine blade component.

[0003] BACKGROUND

[0004] Modern wind turbines are commonly used to supply electricity to the electrical grid. Wind turbines of this kind generally comprise a rotor with a rotor hub and a plurality of wind turbine blades. The rotor is set into rotation under the influence of the wind on the blades. The rotation of the rotor shaft drives the generator rotor either directly (“directly driven”) or through use of a gearbox. The gearbox (if present), the generator and other systems are usually mounted in a nacelle on top of a wind turbine tower.

[0005] Wind turbine blades are generally made from fiber- re info reed polymers or plastics (FRPs), which are composite materials consisting of a polymer matrix and reinforced with fibers. The fibers usually comprise glass or carbon and provide longitudinal stiffness and strength. However, such fibers may become displaced and / or defective. Moreover, recent trends towards increased size of wind turbine blades to capture more wind places greater mechanical stress on wind turbine blades than ever before.

[0006] Hence, there is a need for wind turbine blade components with improved mechanical strength. More specifically, there is a need for wind turbine blade components with reduced susceptibility to displacement of fibers from which they are made and / or reduced defects of wind turbine blade components. There is also a need for an efficient and efficacious manufacturing process of such improved wind turbine blade components.

[0007] SUMMARY

[0008] According to a first aspect of the present disclosure, there is provided a wind turbine blade component for a wind turbine blade. The wind turbine component comprises a main body and a first guide. The main body comprises a plurality of layers, including a first layer and a second layer, the layers being arranged one on top of the other between a first side and a second side thereof, whereby the main body spans a thickness. The layers comprise fiber pultrusions. The first guide, which comprises a porous material, is arranged at the first side of the main body. The first guide comprises a plurality of portions, the portions being arranged one on top of the other. Each of the plurality of portions of the first guide is associated with one or more layers of the plurality of layers. A width of the first portion of the first guide is different to a width of the second portion of the first guide, whereby a plane in which the first layer abuts the first portion of the first guide is misaligned with a plane in which the second layer abuts the second portion of the first guide.

[0009] The first aspect is advantageous, because it facilitates greater mechanical strength of the wind turbine blade component. The presence of the first guide facilitates accurate laying of the fiber pultrusions and discourages movement of the fiber pultrusions during or after manufacture of the wind turbine blade component that may compromise the structural integrity of the wind turbine blade component. The combination of the main body comprising a plurality of layers and the first guide comprising a plurality of portions enables the fiber pultrusions to be laid one at a time (e.g., on a mold surface). Consequently, the portions of the first guide may accommodate small misalignments of the layers of fibers pultrusions. Thus, the chance of overlap or slipping of fiber pultrusions may be reduced. In other words, the likelihood of a fiber pultrusion of one layer protruding into another layer, or a fiber pultrusion of one layer riding another fiber pultrusion of the same layer may be reduced. This arrangement may enable increased strength of the main body.

[0010] Furthermore, the portions of the first guide may enable increased flexibility of the arrangement of the fiber pultrusions. Accordingly, various arrangements of the fiber pultrusions are facilitated. For example, an interlocked or staggered arrangement is provided. In this interlocked arrangement planes of ends of adjacent fiber pultrusions, or planes of an end of a fiber pultrusion and an end of an adjacent portion of the first guide, that meet or abut on consecutive layers are misaligned. These arrangements may effect greater mechanical strength of the wind turbine blade. These arrangements are not possible if, for example, the first guide is integral (i.e., does not comprise a plurality of portions).

[0011] Further, the first aspect is advantageous, because it facilitates the inclusion of interlayer material in the first guide. For instance, a conductive material may be included between consecutive portions of the first guide. The presence of an interlayer material comprising a conductive material reduces the risk of internal flashover between the plurality of layers (e.g., resulting from a lightning strike).

[0012] Additionally, the presence of the first guide, advantageously, reduces the need for mold upstands, meaning that the manufacturing process of the wind turbine blade component is more efficient. For instance, components of the wind turbine blade component may be laid in situ (i.e., directly on a surface of the wind turbine blade), as well as being prefabricated.

[0013] According to a second aspect of the present disclosure, there is provided a method of manufacturing a wind turbine blade component. The method of the second aspect comprises arranging a main body on a mold surface, the main body comprising a plurality of layers, including a first layer and a second layer, arranged one on top of the other between a first side and a second side thereof, whereby the main body spans a thickness. The layers comprise fiber pultrusions. The method of the second aspect comprises arranging a first guide on the mold surface at the first side of the main body. The first guide comprises a plurality of portions, including a first portion and a second portion, arranged one on top of the other. The first guide comprises a porous material. Each of the plurality of portions of the first guide is associated with one or more layers of the plurality of layers. A width of the first portion of the first guide is different to a width of the second portion of the first guide, whereby a plane in which the first layer abuts the first portion of the first guide is misaligned with a plane in which the second layer abuts the second portion of the first guide. The method of the second aspect comprises impregnating the fiber pultrusions with a resin. The method of the second aspect comprises curing the resin to form the wind turbine blade component.

[0014] According to a third aspect of the present disclosure, there is provided a method of manufacturing a wind turbine blade. The method of the third aspect comprises forming an upper blade shell part and a lower blade shell part. Forming the upper blade shell part and / or the lower blade shell part comprises arranging the wind turbine blade component of the first aspect on an outer layer laid in a blade shell part mold. Arranging the wind turbine blade component comprises inserting the wind turbine blade component into a cavity defined by a core material. Forming the upper blade shell part and / or the lower blade shell part comprises bonding the wind turbine blade component to the outer layer. The method of the third aspect comprises joining a reinforcing structure to the upper blade shell part and to the lower blade shell part, such that the reinforcing structure is arranged between the upper blade shell part and the lower blade shell part, and joining the upper blade shell part to the lower blade shell part.

[0015] Advantages derived from the second and third aspects may be the same or similar to those mentioned regarding the first aspect.

[0016] BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Non-limiting examples of the present disclosure will be described in the following, with reference to the appended drawings, in which:

[0018] Figure 1 shows a perspective view of a wind turbine;

[0019] Figure 2 shows a perspective view of a wind turbine blade;

[0020] Figure 3 shows a cross-sectional view of a wind turbine blade;

[0021] Figures 4A, 4B, 4C, 4D and 4E show cross-sectional views of a wind turbine blade component according to different examples;

[0022] Figures 5A and 5B show a plurality of layers and a plurality of portions according to different examples;

[0023] Figure 6 shows a cross-sectional view of the wind turbine blade component including a glass material according to one example;

[0024] Figures 7A and 7B show cross sectional views of a wind turbine blade component suffering from defects according to the prior art and according to one example of the present disclosure, respectively;

[0025] Figures 8A and 8B show cross sectional views of a wind turbine blade component including a lightning connector assembly according to different examples;

[0026] Figure 9 shows a block diagram of a method of manufacturing a wind turbine blade component;

[0027] Figure 10 shows a wind turbine blade component on a mold surface; Figure 11 shows a method of impregnating fiber pultrusions from a bottom of a mold;

[0028] Figure 12 shows a method of impregnating fiber pultrusions from a bottom of a mold;

[0029] Figure 13 shows a method comprising rotating the mold surface;

[0030] Figure 14 shows a method in which the mold comprises two substantially U-shaped components;

[0031] Figure 15 shows a block diagram a method of manufacturing a wind turbine blade; and

[0032] Figure 16 shows a wind turbine blade component in a blade shell part mold.

[0033] DETAILED DESCRIPTION OF EXAMPLES

[0034] Figure 1 shows a perspective view of one example of a wind turbine 1. 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 outwardly from the rotor hub 6. In the illustrated example, the rotor 5 includes three wind turbine blades 7. However, in an alternative example, the rotor 5 may include more or less than three wind turbine blades 7. Each wind turbine blade 7 may be spaced from the rotor hub 6 to facilitate rotating the rotor 5 to enable kinetic energy to be transferred from the wind into usable mechanical energy and, subsequently, electrical energy. For instance, the rotor hub 6 may be rotatably coupled to an electric generator positioned within the nacelle 4 or forming part of the nacelle to permit electrical energy to be produced.

[0035] Figure 2 shows an example of a wind turbine blade 7. The wind turbine blade 7 extends in a longitudinal direction or lengthwise direction 37 from a blade root end 71 to a blade tip end 72. The wind turbine blade 7 comprises a blade root region or portion 50 closest to the rotor hub, a profiled or an airfoil portion 52 furthest away from the rotor hub and a transition portion 51 between the blade root portion 50 and the airfoil portion 52. The wind turbine blade 7 comprises a leading edge 53 facing the direction of rotation of the wind turbine blade 7 when mounted on the rotor hub and a trailing edge 54 facing the opposite direction of the leading edge 53.

[0036] The airfoil portion 52 has a shape designed to generate lift, whereas the blade root portion 50 has a circular or elliptical cross-section for structural considerations and easy mounting of the blade to the rotor hub. The diameter or the chord of the blade root portion 50 may be constant along the entire blade root portion 50. At the transition portion 51 , the profile gradually changes from the circular or elliptical crosssection of the blade root portion 50 to the airfoil profile of the airfoil portion 52. The wind turbine blade 7 may be connected to the rotor hub through a blade root attachment portion 55.

[0037] The wind turbine blade 7 comprises a blade shell 73. The blade shell 73 comprises an outer side or surface that defines the external shape of the blade (e.g., the outer shape at the blade root portion and the outer shape at the airfoil portion). The blade shell 73 also comprises an inner side or surface that defines the internal volume of the blade and faces a load-carrying structure (not shown). The blade shell 73 may be made of fiber- re info reed polymer or plastics (e.g., glass fiber and / or carbon fiber).

[0038] The blade shell may be formed by a plurality of blade shell parts. The plurality of blade shell parts may be joined together to form the blade shell. The blade shell parts may be formed and then joined according to any of the examples herein disclosed. For example, resin infusion technology, such as RTM (resin transfer molding) or VARTM (vacuum assisted resin transfer molding), or prepreg technology may be used for manufacturing the blade shell parts.

[0039] In some examples, the blade shell comprises a lower side blade shell part and an upper blade shell part. The lower side blade shell may be a pressure side blade shell part. The upper blade shell part may be a suction side blade shell part. The lower side blade shell part may be joined to the upper side blade shell part along joining lines along the leading edge 53 and the trailing edge 54. Each of these blade shell parts may be manufactured in a mold and then joined together to define the entire blade shell of the wind turbine blade 7. A reinforcing structure is arranged between the lower side blade shell part and the upper side blade shell part.

[0040] Figure 3 shows a cross-sectional view of a wind turbine blade 7 according to one example of the present disclosure. A suction side blade shell part or upper blade shell part 100 and a pressure side blade shell part or lower blade shell part 200 extend from the leading edge 53 to the trailing edge 54. The wind turbine blade 7 further comprises a chord line 38 between the leading edge 53 and the trailing edge 54. The chord line 38 extends in an edgewise direction or chordwise direction. A flapwise direction 39 is substantially perpendicular to the chord line 38. The upper blade shell part 100 and the lower blade shell part 200 are joined (e.g., bonded) together along the leading edge 53 and the trailing edge 54.

[0041] The upper blade shell part 100 comprises an upper outer layer 101 and an upper inner layer 102. The upper outer layer 101 defines an outer shape of the upper blade shell part 100 and the upper inner layer 102 defines an inner shape of the upper blade shell part 100. The upper outer layer 101 and the upper inner layer 102 may comprise glass fiber laminates. For example, one or more glass fiber laminates may be arranged to form the upper outer layer 101 and / or the upper inner layer 102. The fibers (e.g., glass fibers) may be oriented bidirectionally to enhance the torsional stiffness of the wind turbine blade 7. In other examples, the fibers may be arranged unidirectionally. In further examples, the upper layers 101 and / or 102 comprise laminates with unidirectional fibers and laminates with bidirectional fibers.

[0042] The upper blade shell part 100 of this example comprises an upper spar cap structure 110 embedded between the upper outer layer 101 and the upper inner layer 102. The upper spar cap structure 110 is thus arranged between the upper outer layer 101 and the upper inner layer 102. The upper spar cap structure 110 structurally reinforces the upper blade shell part 100.

[0043] A core material may be arranged between the upper outer layer 101 and the upper inner layer 102 in some parts of the upper blade shell part 100. For example, a core material may extend a portion between the upper spar cap structure 110 and the leading edge 53. Additionally, or alternatively, a core material may extend a portion between the upper spar cap structure 110 and the trailing edge 54. The core material generally increases the thickness of the blade shell part so as to improve the stiffness without an excessive weight increase. The core material may be made from a lightweight material such as wood (e.g., balsa wood) or foam.

[0044] The lower blade shell part 200 may be manufactured like the upper blade shell part 100. As described with respect to the upper blade shell part 100, the lower blade shell part 200 comprises 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 bidirectional glass fibers. A lower spar cap structure 210 is embedded between the lower outer layer 201 and the lower inner layer 202.

[0045] The upper spar cap structure 110 and the lower spar cap structure 210 of this example cross the flapwise direction 39. The spar cap structures 110 and 210 face each other. The spar cap structures 110 and 210 may extend a length along the spanwise direction 37 of the wind turbine blade 7. The length of the spar cap structures 110, 210 may be greater than 90% of the entire length of the wind turbine blade 7.

[0046] The wind turbine blade 7 comprises a reinforcing structure 300 arranged between the upper blade shell part 100 and the lower blade shell part 200. The reinforcing structure 300 provides stiffness to the wind turbine blade 7. The reinforcing structure 300 comprises a first reinforcing beam 310 arranged between the upper spar cap structure 110 and the lower spar cap structure 210. In further examples, the reinforcing structure comprises a first reinforcing beam and a second reinforcing beam.

[0047] The first reinforcing beam 310 of this example extends a length along the spanwise direction 37. The first reinforcing beam 310 may substantially extend between the root portion and the tip portion. The length of the first reinforcing beam 310 may correspond to the length of the spar cap structures 110, 210.

[0048] The first reinforcing beam 310 comprises 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 joined to the upper blade shell part 100. The upper flange 320 is joined (e.g., bonded) to the upper inner layer 102 at the region of the upper spar cap structure 110. Similarly, the lower flange 330 is joined to the lower inner layer 202 at the region of the lower spar cap structure 210. In this example, the first reinforcing beam 310 and the spar cap structures 110, 210 form the load-carrying structure of the wind turbine blade 7 that serves to withstand loads applied to the wind turbine blade 7.

[0049] 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 the flanges 320 and 330. This configuration may be generally known as a spar box configuration. An adjoining or connecting layer may be arranged between the flanges 320 and 330 and the corresponding inner layer 102 and 202. The adjoining or connective layers join the flanges 320 and 330 to the blade shell parts 100 and 200. The adjoining or connective layer may comprise an adhesive layer. The first reinforcing beam 310 may thus be bonded to the upper blade shell part 100 and to the lower blade shell part 200. The spar cap structures 110, 210 are arranged between the corresponding flanges 320, 330 and the outer layer 101 , 201.

[0050] Figure 4A shows a cross-sectional view of a spar cap structure 210, as an example of a wind turbine blade component, arranged in a wind turbine blade 7 according to an example of the present disclosure. Figure 4A relates to a spar cap structure 210 arranged in the lower blade shell part (a lower spar cap).

[0051] The spar cap structure 210 is arranged between the lower outer layer 201 and the lower inner layer 202. The spar cap structure 210 comprises a main body 220 extending between a first side 223 and a second side 224. In this example, the first side 223 is a leading edge side and the second side 224 is a trailing edge side, but other examples may be the opposite. The main body 220 comprises a thickness extending in a direction substantially perpendicular to the flapwise direction 39 (i.e., extending between the lower outer layer 201 and the lower inner layer 202).

[0052] The main body 220 is formed by fiber pultrusions 261, 262, 263, 264, 265, 266 between the first side 223 and the second side 224. Specifically, the main body is formed of a plurality of layers 271 , 272 arranged one on top of the other, thereby, at least in part, defining a thickness of the main body 220. In the example shown in Figure 4A, a second layer 272 is shown arranged on top of a first layer 271. In the example shown in Figure 4A, each of the plurality of layers 271 , 272 comprises three fiber pultrusions, but any number of fiber pultrusions per layer is possible in principle.

[0053] The main body 220 may extend a body length in a direction parallel to the spanwise or lengthwise direction 37 of the wind turbine blade 7 along a length of the corresponding spar cap structure 210. Lengths of the fiber pultrusions of a layer may vary along the spanwise direction so as to form a stepwise configuration. Some fiber pultrusions of a layer may extend the entire length of the spar cap structure 210.

[0054] The spar cap structure 210 also comprises a first guide 240. The first guide 240 is arranged at the first side 223 of the main body 220. In some examples, the first guide 240 is merely proximal to or in contact with the first side 223. In other examples, the first guide 240 is attached (e.g., infused) with the first side 223. Advantageously, the presence of the first guide 240 facilitates accurate laying of the fiber pultrusions 261 , 262, 263, 264, 265, 266 and may discourage (e.g., lateral) movement thereof during or after manufacture of the wind turbine blade component that would compromise its structural integrity. The first guide 240 comprises a plurality of portions 241, 242 arranged one on top of the other. In the example shown in Figure 4A, a second portion 242 is shown arranged on top of a first portion 241.

[0055] Each of the plurality of portions 241, 242 of the first guide 240 is associated with one or more layers of the plurality of layers 271 , 272 of the main body 220. In the example shown in Figure 4A, each of the plurality of portions 241, 242 of the first guide 240 is associated with one of the plurality of layers 271 , 272 of the main body 220. Namely, the first portion 241 is associated with the first layer 271 , and the second portion 242 is associated with the second layer 272. To this end, in the example shown in Figure 4A, a height of the first portion 241 of the first guide 240 corresponds to a height of the first layer 271 of the main body 220, and a height of the second portion 242 of the first guide 240 corresponds to a height of the second layer 272 of the main body 220. The first guide 240 comprising a plurality of portions, in particular each of the plurality of portions 241 , 242 of the first guide 240 being associated with one of the plurality of layers 271, 272 of the main body 220, enables the fiber pultrusions 261, 262, 263, 264, 265, 266 to be laid one at a time. Being able to lay the fiber pultrusions 261, 262, 263, 264, 265, 266 one at a time may facilitate various improved arrangements, as described below.

[0056] In the arrangement shown in Figure 4A, first layer 271 abuts the first portion 241 of the first guide 240, and the second layer 272 abuts the second portion 242 of the first guide 240. The first layer 271 and the second layer 272 abutting, respectively, the first portion 241 and the second portion 242 means that an end of the first layer 271 meets an end of the first portion 241 , and an end of the second layer 272 meets and end of the second portion 242. The first layer 271 and the second layer 272 abutting, respectively, the first portion 241 and the second portion 242 does not necessarily mean that respective layers 271, 272 and portions 241 , 242 are in contact. The term “abut” is used in this sense throughout the description.

[0057] The first guide 240 may comprise an interlayer material between adjacent or consecutive portions of the plurality of portions. For example, the first guide 240 may comprise an interlayer between the first portion 241 and the second portion 242. The interlayer material may extend between the adjacent portions of the plurality of portions from the main body 220. For instance, the first layer 271 and the second layer 272 may have an interlayer material therebetween, and this interlayer material may continue between the first portion 241 and the second portion 242.

[0058] The interlayer material has a higher electrical conductivity than resin used to impregnate the fiber pultrusions. Resin and any gaps between the fiber pultrusions may hinder a lightning current from flowing the fiber pultrusions, increasing risk of internal flashover between the plurality of layers, which may potentially damage the wind turbine blade component. Advantageously, the interlayer material may reduce this risk, especially in the case the fiber pultrusions comprise carbon fiber pultrusions (see below paragraph). In some examples, the interlayer material comprises carbon fibers. The interlayer material may alternatively or additionally comprise metal (e.g., copper, such as copper filaments, and / or steel). In some examples, the interlayer material comprises carbon fibers in the form of carbon fiber fabric and / or metal conductive wires. The carbon fibers may be arranged in a biaxial configuration. In further examples, the interlayer material comprises a hybrid fiber configuration, such as glass / carbon fiber fabric or woven material.

[0059] The fiber pultrusions 261, 262, 262, 264, 265, 266 may comprise carbon fiber pultrusions. The fiber pultrusions 261, 262, 262, 264, 265, 266 may additionally or alternatively comprise other materials (e.g., glass fiber pultrusions and / or aramid fiber pultrusions). Advantageously, carbon fiber pultrusions may offer a better stiffness / weight ratio and fatigue properties than glass fibers (e.g., glass fiber pultrusions).

[0060] Figure 4B shows a cross-sectional view of a spar cap structure 210, as an example of a wind turbine blade component, according to another example of the present disclosure. As alluded to, the main body 220 is not limited to a particular number of layers. Whereas Figure 4A shows a second layer 272 arranged on top of a first layer 271 , Figure 4B shows four layers 271, 272, 273 and 274 arranged one on top of the other. In other words, Figure 4B shows a fourth layer 274, a third layer 273, the second layer 272 and the first layer 271 arranged on top of each other in turn. Similarly, the first guide 240 shown in Figure 4B comprises the first portion 241, the second portion 242, a third portion 243 and a fourth portion 244 arranged one on top of the other. Figure 4B also differs from Figure 4A in that the wind turbine blade component of Figure 4B includes a second guide 250 in addition to the first guide 240 at the first side 223 in Figure 4A. The second guide 250 is at the second side 224 of the main body 220. In some examples, the second guide 250 is merely proximal to or in contact with the second side 224. In other examples, the second guide 250 is attached (e.g., infused) with the second side 224. Details described herein relating to the first guide 240 apply correspondingly to the second guide 250. For instance, the second guide may comprise a plurality of portions, the portions being arranged one on top of the other, as shown in Figure 4B, and these portions may be respectively associated with the plurality of layers 271 , 272, 273, 274. As shown in Figure 4B, the wind turbine blade component may have a curved or rounded form.

[0061] The first guide 240 comprises a different material to the main body 220. Namely, the first guide 240 comprises a porous material (e.g., foam or balsa wood). The second guide 250 may also comprise a porous material. In an example of the first guide 240 and or the second guide 250 comprising foam, the foam may have a PET value of between 70 and 400. For example, the foam may have a PET value of 110 or 200. The foam may comprise PVC foam. Advantageously, the first guide 240 and / or second guide comprising foam may facilitate manufacture of portions of different widths.

[0062] Figure 4C shows a cross-sectional view of a spar cap structure 210, as an example of a wind turbine blade component, according to another example of the present disclosure. Figure 4C corresponds to Figure 4B apart from the arrangement of the plurality of layers and the plurality of portions.

[0063] The plurality of portions of the first guide 240 shown in Figure 4C includes the first portion 241, the second portion 242, the third portion 243 and the fourth portion 244. The first layer 271 comprises a fiber pultrusion 261 , a fiber pultrusion 262 and a fiber pultrusion 263. The second layer 272 comprises a fiber pultrusion 264, a fiber pultrusion 265 and a fiber pultrusion 266.

[0064] A plane 291 in which the fiber pultrusion 261 abuts the fiber pultrusion 262 is misaligned with a plane 292 in which the fiber pultrusion 264 abuts the fiber pultrusion 265. As can be seen from Figure 4C, this structure is repeated for adjacent layers (e.g., the third layer 273 and the fourth layer 274). In other words, for adjacent or consecutive layers of the plurality of layers, there is misalignment between planes in which the fiber pultrusions abut (i.e. , meet or face). The resulting structure is herein termed an interlocked or staggered arrangement. Advantageously, this interlocked arrangement may reduce the chance of overlap, whereby a fiber pultrusion of one layer protrudes into another layer. Further advantageously, this interlocked arrangement may remove the vertical seam, thereby increasing the mechanical strength of the wind turbine blade component (e.g., transversal weakness across the main body 220 is reduced). Relatedly, the interlocked arrangement may facilitate the curved or rounded form of the wind turbine blade component.

[0065] This interlocked or staggered arrangement, as shown in Figure 4C, is also found at the interface between each of the guides 240, 250 and the main body 220. For example, a plane 293 in which the first portion 241 of the first guide 240 abuts the fiber pultrusion 261 is misaligned with a plane 294 in which the second portion 242 of the first guide abuts the fiber pultrusion 264. In other words, a width of the first portion 241 of the first guide is be different to a width of the second portion 242 of the first guide. The width of the first portion 241 and the second portion may be different to accommodate or compensate for the misalignment of the fiber pultrusions. More generally, there may be two groups of portions, the first group of portions having the same width as the first portion 241 and the second group of portions having the same width as the second portion 242. Portions belonging to the first group of portions may have a width that is between 40% and 90% of the portions belonging to the second group of portions. Advantageously, having an interlocked arrangement at the interface may increase the strength of the interface. Further, advantageously, this arrangement may enable fiber pultrusions of the same width to be used in the manufacture of the wind turbine blade component, meaning that costs associated with requiring a different die for each fiber pultrusion geometry and managing multiple fiber pultrusion geometries may be avoided.

[0066] Figures 4D and 4E show cross-sectional views of a spar cap structure 210, as an example of a wind turbine blade component, according to other examples of the present disclosure. Figures 4D and 4E correspond to Figure 4C apart from the degree of misalignment of the aforementioned planes / degree of interlocking. As can be seen from comparing Figures 4C and 4D, the greater the curvature of the cross section of the wind turbine blade component, the greater the degree of misalignment (e.g., the degree of misalignment shown in Figures 4C and 4D may be less than 10% and greater than 10%, respectively), the greater the size of the gaps between components. These gaps may cause resin pools to form, on impregnating the plurality of fiber pultrusions with a resin to bond them (see below description of methods). If wind turbine blade component has a flat cross section, as per Figure 4E, the degree of misalignment has no bearing on the size of the gaps.

[0067] Figures 5A and 5B show the plurality of layers and the plurality of portions in isolation from other components of the wind turbine blade component according to different examples.

[0068] The plurality of layers shown on the left side in both Figures 5A and 5B are plates. In other words, the width of each layer is several times its thickness (e.g., greater than ten times). In some examples, a plate comprises a width between 20 mm and 300 mm and a thickness between 1 mm and 6 mm (e.g., 5 mm). In other examples, each of the plurality of layers comprises other suitable cross-sectional shapes (e.g., a rectangular cross-section). These plates may be used in any of the examples of Figures 4A to 4E.

[0069] The plurality of portions shown on the right side in Figure 5A are plates, having the same form as the plurality of layers. In contrast to Figure 5A, each of the plurality of portions shown on the right side of Figure 5B are L-shaped. In this example, a height of the first portion 241 corresponds to a combined height of the first layer 271 and the second layer 272.

[0070] Figure 6 shows cross-sectional views of a spar cap structure 210, as an example of a wind turbine blade component, according to another example. Figure 6 corresponds to Figure 5B with the addition of a glass material 400. The glass material 400 encapsulates the main body 220, the first guide 240 and the second guide 250. In the case that the wind turbine blade component does not comprise the second guide 250 (e.g., Figure 4A), the glass material 400 encapsulates the main body 220 and the first guide 240. Encapsulating the main body 220 and the guide(s) 240, 250, means that the glass material 400 surrounds them. Encapsulating components of the wind turbine blade component with the glass material 400, advantageously, may help to keep these components together. Handling operations of the spar cap 210, advantageously, may thus be improved.

[0071] Figure 7A shows a wind turbine blade component according to the prior art to aid understanding of the present disclosure. Figure 7A shows the wind turbine blade component between a pair of upstands 512 and on a mold surface 513. As shown in Figure 7A, defects 500 (e.g., air pockets or bubbles) may form in the main body 220 when the fiber pultrusions are impregnated with resin, in which a vacuum is applied via an outlet 511 of the glass material 400.

[0072] Figure 7B shows a wind turbine component according to one example of the present disclosure. In contrast to Figure 7A, Figure 7B does not show any upstands, the reason being that the guides 240, 250 negate the need for such upstands 512 by performing the role of upstands. By applying a vacuum via an outlet 511 of the glass material 400 at a position over one of the guides 240, 250 (e.g., the first guide 240, as in Figure 7B), as described in more detail below in relation to Figures 9 and 10, as opposed to a position over the main body 220 (see Figure 7A), in the case that the guides 240, 250 comprise a porous material such as foam (irrespective of the whether the guides 240, 250 comprise portions or the number of those portions), defects 500 can be encouraged to move from the main body 220 to the guides 240, 250. Therefore, advantageously, the structural integrity of the main body 220 may be maintained by use of a one or more guides 240, 250 comprising foam.

[0073] The wind turbine blade component may comprise a lightning connector assembly arranged at the first side 223 or the second side 224. The lightning connector assembly is particularly useful in the case that the fiber pultrusions comprise carbon fiber pultrusions. For example, the first guide 240 or the second guide 250 may comprise the lightning connector assembly. The lightning connector assembly is connectable to a lightning protection system of the wind turbine blade 7, advantageously, enabling electrical connection of the wind turbine blade component to a down conductor.

[0074] Figure 8A shows the wind turbine blade component with the same interlocked arrangement as Figure 4D, but with a greater number of layers of fiber pultrusions, in which the second guide 250 comprises a lightning connector assembly. The lightning connector assembly shown in Figure 8A comprises a carbon biax patch 610, a disc 620 and a lightning receptor 630. The carbon biax patch 610 replaces the uppermost one of the plurality of portions of the second guide 250, connecting the main body 220 to the lighting receptor assembly. Thus, the carbon biax patch may be, for example, 5mm thick (i.e., the same thickness as the portion of the second guide 250 which it has replaced). The carbon biax patch 610 may comprise quasi isotropic carbon. In another example, the carbon biax patch 610 is formed by chopped carbon fibers in a resin matrix. The carbon biax patch 610 may comprise metal (e.g., steel or copper). In other examples, the carbon biax patch 610 may be a different thickness than the portion of the second guide 250 which it has replaced. The carbon biax patches 610, advantageously, provide structural support for the disc 620 the lightning receptor 630 and provide electrical conductivity between the main body 220 and the disc 620. The disc 620 may comprise copper, due to copper's high electrical conductivity. The lightning receptor 630 is substantially parallel to the second side 224 and passes through a hole in the first portion of the second guide 250 such that a current path may, advantageously, be created towards the down conductor.

[0075] As shown in Figure 8B, a set of the plurality of portions of the second guide 250 may be replaced by carbon biax patches 610 in order to, advantageously, enhance electrical conduction from the main body 220 to the lightning receptor assembly compared with the arrangement shown in Figure 8A. While an interlocked arrangement is shown in Figures 8A and 8B, it should be noted that the lightning connector assembly may be implemented with the structures shown in Figure 4A and 4B.

[0076] Figure 9 shows a block diagram of a method of manufacturing the wind turbine blade component, as described above, according to any example of the present disclosure. Figure 9 can be best understood when considered in conjunction with Figure 10, which shows a wind turbine blade component of having the interlocked arrangement of Figure 4C and including the glass material 400 described in relation to Figure 6 on a mold surface 513.

[0077] As shown in Figure 9, the method of manufacturing the wind turbine blade component comprises arranging 710 the main body 220, which is detailed above, on the mold surface 513, arranging 720 the first guide 240, also detailed above, on the mold surface 513, impregnating 730 the fiber pultrusions of the main body 220 with a resin and curing 740 the resin to form the wind turbine blade component. The arranging 710 may precede or follow the arranging 720. Advantageously, in this way, the wind turbine blade component may be prefabricated or may be fabricated in situ. In other words, the wind turbine blade component may be manufactured in isolation from other components of the wind turbine blade or may be manufactured on a mold surface 513, where the mold surface 513 is a surface of the wind turbine blade 7 (e.g., the outer layer 201). Arranging 710 the main body 220 and arranging 720 the first guide 240 may comprise placing the layers one at a time and placing the portions one at a time, respectively.

[0078] The method may comprise attaching (e.g., infusing) the first guide 240 at the first side of the main body 220. The method may comprise arranging the second guide 250 on the mold surface 513. The presence of the first guide 240 and / or the second guide 250, negates the need to mold upstands 512, contributing to enabling fabrication in situ and / or with simple tools.

[0079] Impregnating 730 the fiber pultrusions (i.e., the fiber pultrusion stack) with resin may comprise arranging a vacuum bag 820 over the fiber pultrusions and sealing the vacuum bag 820 to the mold surface 513 to define a mold cavity. For example, the vacuum bag 820 may be sealed to the mold surface 513 at affixation points 830. Impregnating 730 the fiber pultrusions with resin may also comprise generating a vacuum in the mold cavity and supplying resin to the mold cavity to fill the mold as part of a resin infusion process. For example, a vacuum may be generated in the mold cavity by applying a vacuum using a vacuum pump attached to the vacuum bag 820 via a suction point or outlet 840. Resin may also impregnate the guides 240, 250 depending on the vertical gaps between the portions.

[0080] Arranging the vacuum bag 820 over the fiber pultrusions may comprise arranging the vacuum bag 820 over the first guide 240 and or the second guide 250. In Figure 10, the vacuum bag 820 is arranged over the first guide 240 and the second guide 250. In other words, the mold cavity includes the fiber pultrusions, the first guide 240 and the second guide 250. In the context of the guides 240, 250, arranging the vacuum bag 820 over the guides 240, 250, means arranging the vacuum bag 820 over and around the guides 240, 250. Arranging the vacuum bag over and around the first guide 240 and / or the second guide 250 means that the vacuum bag 820 is arranged over an external face of the first guide 240 and / or the second guide 250. The external face 850 of the first guide 240, for instance, is the face opposite the interface between the first guide 240 and the fiber pultrusions (internal face 860).

[0081] Arranging the vacuum bag over and around the first guide 240 may comprise arranging the outlet 840 of the vacuum bag 820 over the first guide 240. As described in relation to Figures 7A and 7B, defects 500 can be encouraged to move from the main body 220 to the guides 240, 250. Therefore, advantageously, the structural integrity of the main body 220 can be maintained. Relatedly, the method may comprise cutting away or trimming a region of the first guide 240 or (e.g., a region of the first guide 240 to which defects 500 have moved), thereby resulting in a wind turbine blade component which is free from defects 500. Cutting away the region of the first guide 240 may also enable alterations for a desired geometry. In the event that a region of the first guide 240 is cut away or trimmed, the method may comprise replacing the region.

[0082] In one example, the method shown in Figure 11 comprises impregnating 730 the fiber pultrusions with resin from a bottom of the mold (e.g., at the mold surface 513). In other words, resin may enter where its gravitational potential energy is lowest. Impregnating 730 the fiber pultrusions with resin from the bottom of the mold, advantageously, discourages defects (e.g., air bubbles) from forming during the impregnating 730. In particular, if the outlet 840 is opposite the point of ingress of resin (e.g., in a plane opposite a plane of the point of ingress), formation of defects may be avoided. Having a void-free structure is important for structural integrity and strength.

[0083] In one example, the method may comprise, in addition to arranging 710 spar cap structures 110, 120 (i.e., main body 220) on a mold surface 513, arranging a web 340 (see Figure 3) on the mold surface 513. As shown in Figure 11 , the spar cap structures 110, 210 and the web 340 may be placed on the mold surface 513. One or more inlays 514 may be used to maintain the position of the web 340. Advantageously, therefore, manufacture of the wind turbine blade component may be performed in a modular manner. Further advantageously, impregnating both spar cap structures 110, 210 and the web 340 using a single mold is more efficient than conventional methods, which require more than one mold. Relatedly, this method may, advantageously, eliminate the bond line between the web 340 and the spar cap structure 110, 210.

[0084] As discussed earlier, impregnating 730 may involve resin entering at the bottom of the mold to reduce the likelihood of formation of defects. In Figure 11, resin may enter at ingress points 845. A plurality of outlets 840 may be used to encourage the resin to flow as one front, thereby further reducing the likelihood of defects forming.

[0085] As shown in Figure 12, the web 340 may be split into two web portions 341 , 342 that are connected by a joint 343. The ends of the web portions 341, 342 may be connected at the joint by an adhesive material. Several types of joint are possible, including, but not limited to, a scarf joint, a butt joint, a snap-fit joint and an H- connector joint.

[0086] In one example, the method may comprise rotating the mold surface 513 to a substantially vertical position before impregnating 730 the fiber pultrusions with resin. This feature may be understood with reference to Figure 13.

[0087] Figures 13(a) to 13(c) show arranging 710 of the main body 220 on the mold surface 513. The mold includes the mold surface 513 and a pivotable, substantially U-shaped component 515. The U-shaped component 515 comprises a base segment 516, a first side segment 517 and a second side segment 518. The side segments 517, 518 are parallel to each other and attached substantially perpendicularly to the base segment 516. In Figures 13(a) to 13(c) the first side segments extend from the mold (i.e., a side wall of the mold upstanding from the mold surface 513) such that the base segment 516 is above and adjacent to the mold surface 513, extending in a direction parallel thereto.

[0088] In Figure 13(d) the glass material 400 is included, though the glass material 400 is not essential. In Figure 13(d), the substantially U-shaped component 515 has been rotated such that the base segment 516 has moved through 90 degrees anticlockwise, whereby the first side segment 517 rests on the main body 220 and the base segment 516 is substantially perpendicular to the main body 220.

[0089] In Figure 13(e), the web 340 has been incorporated. In the example shown in Figure 13(e), the web 340 been placed beneath the glass material 400. As shown in Figure 13(e), the base segment 516 supports the web 340. In other words, the web 340 rests on or against the base segment 516.

[0090] In Figure 13(f), the mold has been rotated clockwise through 90 degrees such that the mold rests on one of its side walls and the longitudinal axis of the main body 220 is perpendicular to the surface on which the mold is resting (e.g. the ground). The web 340 is now parallel to the surface on which the mold is resting, the web 340 continuing to be supported by the base segment. The mold and, consequently, the main body 220 and web 340 are stabilized by the first side segment 517 and the second side segment 518.

[0091] Once the orientation shown in Figure 13(f) has been realized, as discussed in relation to Figure 11 , the fiber pultrusions may be impregnated with resin via an ingress point 845 at the bottom of the mold at a surface on which the mold is resting. Advantageously, infusing 730 the fiber pultrusions using the arrangement and orientation shown in Figure 13(f) particularly prevents the formation of defects that may be caused by entrapment of air.

[0092] Subsequently, the mold is returned to the orientation shown in Figures 13(a) to 13(e) by rotation anticlockwise through 90 degrees. The mold can then be removed by rotating the substantially U-shaped component 515 such that the base segment 516 is returned to the position shown in Figures 13(a) to 13(c).

[0093] Figure 14 shows a similar method to that shown in Figure 13. The difference between the mold of Figures 13 and 14 is that in Figure 14 the mold comprises a second substantially U-shaped component 515b. The second substantially U-shaped component is operable in a manner analogous to the substantially U-shaped component 515. In other words, the movement of the second substantially U- component element 515b in the method mirrors that of the substantially U-shaped component 515 described above. Consequently, as shown in Figures 14(d) and 14(e), the base segment 516 of the substantially U-shaped component 515 and the base segment 516b of the second substantially U-shaped segment 515 can be drawn together so that they are aligned with each other and perpendicular to the main body 220. In this configuration, the respective base segments 516, 516b accommodate and / or sandwich the web 340. Advantageously, in this way, the web 340 may be held more securely compared with the method shown in Figure 13. Further advantageously, this configuration may serve to reduce the chance of overlap, because the fiber pultrusions are held in the mold by the base segments 516, 516b.

[0094] Once in this so-called “closed” configuration, the fiber pultrusions may be impregnated with resin via an ingress point 845 at the bottom of the mold at a surface on which the mold is resting. The mold can then be removed by rotating the substantially U-shaped components 515, 515b such that the base segments 516, 516b are returned to the positions shown in Figures 14(a) to 14(c).

[0095] The method shown in Figures 13 and 14 may be used for more than one web 340 at a time. In other words, the spar cap structure 110, 210 may be produced with more than one web at a time using these methods.

[0096] Figure 15 shows a block diagram a method of manufacturing a wind turbine blade, according to any example of the present disclosure. Figure 15 can be best understood when considered in conjunction with Figure 16, which shows the wind turbine blade component having the interlocked arrangement of Figure 4C and including the glass material 400 described in relation to Figure 6 in a lower blade shell part 100 supported by a blade shell part mold 1000.

[0097] The method comprises forming 910 the upper blade shell part 100 and the lower blade shell part 200 (see Figure 3). Forming 910 the upper blade shell part 100 and / or the lower blade shell part 200 comprises arranging the wind turbine blade component, as detailed above, on the outer layer 201 laid in a blade shell part mold 1000. Arranging the wind turbine blade component (e.g., a spar cap 210) comprises inserting the wind turbine blade component into a cavity defined by the core material 1100 and bonding the wind turbine blade component to the outer layer 201. The core material 1100 may be the same material as one or both of the guides 240, 250 (e.g., foam). The cavity may have a geometry which is complementary to that of the wind turbine blade component to, advantageously, securely accommodate the wind turbine blade component. The cavity or receiving part may be between the wind turbine blade component and the core material 1100.

[0098] The method also comprises joining 920 the reinforcing structure 300 (see Figure 3) to the upper blade shell part 100 and to the lower blade shell part 200 such that the reinforcing structure 300 is arranged between the upper blade shell part 100 and the lower blade shell part 200 and joining 930 the upper blade shell part 100 to the lower blade shell part 200. The blade shell parts may be bonded together through bonding lines formed at the leading edge 53 and at the trailing edge 54.

[0099] The method may comprise placing an inner layer 1200 over the core material 1100. The inner layer 1200 may also partly or fully encapsulate the core material 1100. The inner layer 1200 may at least partially extend over the wind turbine blade component. For example, the inner layer 1200 may overlap transitional regions between the wind turbine blade component and the core material 1100. For instance, the inner layer may overlap the first guide 240 and / or the main body 220 at the first side 223, and the inner layer 1200 may overlap the second guide 250 and / or the main body 220 at the second side 224. Advantageously, the inner layer 1200 secures the wind turbine blade component.

[0100] For reasons of completeness, various aspects of the present disclosure are set out in the following numbered clauses:

[0101] Clause 1 : A wind turbine blade component for a wind turbine blade, the wind turbine component comprising: a main body comprising a plurality of layers, including a first layer and a second layer, the layers being arranged one on top of the other between a first side and a second side thereof, whereby the main body spans a thickness, wherein the layers comprise fiber pultrusions; and a first guide comprising a porous material arranged at the first side of the main body, wherein the first guide comprises a plurality of portions, including a first portion and a second portion, the portions being arranged one on top of the other, wherein each of the plurality of portions of the first guide is associated with one or more layers of the plurality of layers, wherein a width of the first portion of the first guide is different to a width of the second portion of the first guide, whereby a plane in which the first layer abuts the first portion of the first guide is misaligned with a plane in which the second layer abuts the second portion of the first guide.

[0102] Clause 2: The wind turbine blade component of clause 1, wherein the first guide is attached to the first side.

[0103] Clause 3: The wind turbine blade component of clause 1 or 2, wherein a height of the first portion of the first guide corresponds to a height of the first layer, and a height of the second portion of the first guide corresponds to a height of the second layer.

[0104] Clause 4: The wind turbine blade component of any preceding clause, wherein the first layer abuts the first portion of the first guide, and the second layer abuts the second portion of the first guide.

[0105] Clause 5: The wind turbine blade component of any preceding clause, wherein the first layer comprises a first fiber pultrusion and a second fiber pultrusion and the second layer comprises a third fiber pultrusion and a fourth fiber pultrusion, and wherein a plane in which the first fiber pultrusion abuts the second fiber pultrusion is misaligned with a plane in which the third fiber pultrusion abuts the fourth fiber pultrusion. Clause 6: The wind turbine blade component of any preceding clause , wherein a height of the first portion of the first guide corresponds to a height of the first layer and of the second layer.

[0106] Clause 7: The wind turbine blade component of any preceding clause, wherein the plurality of portions of the first guide comprises a plate-shape portion and / or an L- shape portion.

[0107] Clause 8: The wind turbine blade component of any preceding clause, wherein the first guide comprises an interlayer material between adjacent portions of the plurality of portions.

[0108] Clause 9: The wind turbine blade component of any preceding clause, further comprising: a second guide arranged at the second side of the main body.

[0109] Clause 10: The wind turbine blade component of clause 9, wherein the second guide is attached to the second side.

[0110] Clause 11 : The wind turbine blade component of clause 9 or 10, wherein the second guide comprises a plurality of portions, the portions being arranged one on top of the other.

[0111] Clause 12: The wind turbine blade component of clause 11 , wherein each of the plurality of portions of the second guide is associated with one or more layers of the plurality of layers.

[0112] Clause 13: The wind turbine blade component any of clauses 9 to 12, wherein the second guide comprises a porous material.

[0113] Clause 14: The wind turbine blade component of any preceding clause, wherein the porous material comprises foam, wherein the foam has a PET value of between 70 and 400.

[0114] Clause 15: The wind turbine blade component of any preceding clause, wherein the fiber pultrusions are carbon fiber pultrusions. Clause 16: The wind turbine blade component of any preceding clause, further comprising: a glass material encapsulating the main body and at least one of the first guide and the second guide.

[0115] Clause 17: The wind turbine blade component of any preceding clause, wherein the first guide comprises a lightning connector assembly connectable to a lightning protection system of a wind turbine blade.

[0116] Clause 18: The wind turbine blade component of clause 17, wherein the first guide comprises a carbon biax patch configured to electrically connect the main body to the lightning connector assembly.

[0117] Clause 19: The wind turbine blade component of any preceding clause, wherein the wind turbine blade component is a spar cap structure.

[0118] Clause 20: A wind turbine blade comprising a wind turbine blade component according to any of clauses 1 to 19.

[0119] Clause 21 : A method of manufacturing a wind turbine blade component, the method comprising: arranging a main body on a mold surface, the main body comprising a plurality of layers, including a first layer and a second layer, arranged one on top of the other between a first side and a second side thereof, whereby the main body spans a thickness, wherein the layers comprise fiber pultrusions; arranging a first guide on the mold surface at the first side of the main body, wherein the first guide comprises a plurality of portions, including a first portion and a second portion, arranged one on top of the other, wherein the first guide comprises a porous material, wherein each of the plurality of portions of the first guide is associated with one or more layers of the plurality of layers, and wherein a width of the first portion of the first guide is different to a width of the second portion of the first guide, whereby a plane (293) in which the first layer abuts the first portion of the first guide is misaligned with a plane (294) in which the second layer abuts the second portion of the first guide; impregnating the fiber pultrusions with a resin; and curing the resin to form the wind turbine blade component. Clause 22: The method of clause 21 , further comprising: rotating the mold surface to a substantially vertical position before impregnating the fiber pultrusions with the resin.

[0120] Clause 23: The method of clause 21 or 22 further comprising: impregnating the fiber pultrusions with the resin from a bottom of the mold.

[0121] Clause 24: The method of any of clauses 21 to 23, wherein impregnating the fiber pultrusions with resin comprises: arranging a vacuum bag over the fiber pultrusions and sealing the vacuum bag to the mold surface to define a mold cavity; generating a vacuum in the mold cavity; and supplying resin to the mold cavity to fill the mold.

[0122] Clause 25: The method of clause 24, wherein arranging the vacuum bag over the fiber pultrusions comprises arranging the vacuum bag over and around the first guide.

[0123] Clause 26: The method of clause 25, wherein the first guide comprises an internal face at the first side and an external face opposite the internal face, and wherein arranging the vacuum bag over and around the first guide comprises arranging the vacuum bag over the external face of the first guide.

[0124] Clause 27: The method of clause 25 or 26, wherein arranging the vacuum bag over and around the first guide comprises arranging an outlet of the vacuum bag over the first guide.

[0125] Clause 28: The method of clause 27, wherein the outlet is opposite the mold surface.

[0126] Clause 29: The method of any of clauses 21 to 28, further comprising: cutting away a region of the first guide.

[0127] Clause 30: A method of manufacturing a wind turbine blade, the method comprising: forming an upper blade shell part and a lower blade shell part, wherein forming the upper blade shell part and / or the lower blade shell part comprises: arranging the wind turbine blade component of any of clauses 1 to 19 on an outer layer laid in a blade shell part mold, wherein arranging the wind turbine blade component comprises inserting the wind turbine blade component into a cavity defined by a core material; and bonding the wind turbine blade component to the outer layer; joining a reinforcing structure to the upper blade shell part and to the lower blade shell part such that the reinforcing structure is arranged between the upper blade shell part and the lower blade shell part; and joining the upper blade shell part to the lower blade shell part.

[0128] Clause 31 : The method of clause 30, wherein the core material comprises the same material as the first guide.

[0129] Clause 32: The method of clause 30 or 31 , further comprising: placing an inner layer over the core material.

[0130] Clause 33: The method of clause 32, wherein the inner layer at least partially extends over the wind turbine blade component.

[0131] Clause 34: A method of manufacturing a wind turbine blade component, the method comprising: arranging a main body on a mold surface, the main body comprising a plurality of layers arranged one on top of the other between a first side and a second side thereof, whereby the main body spans a thickness, wherein the layers comprise fiber pultrusions; impregnating the fiber pultrusions with a resin from a bottom of the mold; and curing the resin to form the wind turbine blade component.

[0132] Clause 35: The method of clause 34, further comprising: arranging a web on the mold surface; and impregnating the web with the resin from the bottom of the mold.

[0133] Clause 36: The method of clause 35, further comprising: rotating the mold surface to a substantially vertical position before impregnating the fiber pultrusions with the resin.

[0134] Clause 37: The method of any of clauses 34 to 36, wherein the wind turbine blade component is according to any of clauses 1 to 19.

Claims

CLAIMS1. A wind turbine blade component for a wind turbine blade (7), the wind turbine blade component comprising: a main body (220) comprising a plurality of layers (271, 272), including a first layer (271) and a second layer (272), the layers being arranged one on top of the other between a first side (223) and a second side (224) thereof, whereby the main body spans a thickness, wherein the layers comprise fiber pultrusions (261 , 262, 263, 264, 265, 266); and a first guide (240) comprising a porous material arranged at the first side of the main body, wherein the first guide comprises a plurality of portions (241, 242), including a first portion (241) and a second portion (242), the portions being arranged one on top of the other, wherein each of the plurality of portions of the first guide is associated with one or more layers of the plurality of layers, wherein a width of the first portion of the first guide is different to a width of the second portion of the first guide, whereby a plane (293) in which the first layer abuts the first portion of the first guide is misaligned with a plane (294) in which the second layer abuts the second portion of the first guide.

2. The wind turbine blade component of claim 1 , wherein the first guide is attached to the first side.

3. The wind turbine blade component of claim 1 or 2, wherein a height of the first portion of the first guide corresponds to a height of the first layer, and a height of the second portion of the first guide corresponds to a height of the second layer.

4. The wind turbine blade component of any preceding claim, wherein the first layer comprises a first fiber pultrusion (261) and a second fiber pultrusion (262) and the second layer comprises a third fiber pultrusion (264) and a fourth fiber pultrusion (265), and wherein a plane (291) in which the first fiber pultrusion abuts the second fiber pultrusion is misaligned with a plane (292) in which the third fiber pultrusion abuts the fourth fiber pultrusion.

5. The wind turbine blade component of any preceding claim, wherein the first guide comprises an interlayer material between adjacent portions of the plurality of portions.

6. The wind turbine blade component of any preceding claim, further comprising: a second guide (250) arranged at the second side of the main body.

7. The wind turbine blade component of any preceding claim, further comprising: a glass material (400) encapsulating the main body and at least one of the first guide and the second guide.

8. A method of manufacturing a wind turbine blade component, the method comprising: arranging (710) a main body (220) on a mold surface (513), the main body comprising a plurality of layers (271, 272), including a first layer (271) and a second layer (272), arranged one on top of the other between a first side (223) and a second side (224) thereof, whereby the main body spans a thickness, wherein the layers comprise fiber pultrusions (261 , 262, 263, 264, 265, 266); arranging (720) a first guide (240) on the mold surface at the first side of the main body, wherein the first guide comprises a plurality of portions (241, 242), including a first portion (241) and a second portion (242), arranged one on top of the other, wherein the first guide comprises a porous material, wherein each of the plurality of portions of the first guide is associated with one or more layers of the plurality of layers, and wherein a width of the first portion of the first guide is different to a width of the second portion of the first guide, whereby a plane (293) in which the first layer abuts the first portion of the first guide is misaligned with a plane (294) in which the second layer abuts the second portion of the first guide; impregnating (730) the fiber pultrusions with a resin; and curing (740) the resin to form the wind turbine blade component.

9. The method of claim 8, further comprising: rotating the mold surface to a substantially vertical position before impregnating the fiber pultrusions with the resin.

10. The method of claim 8 or 9, further comprising: impregnating the fiber pultrusions with the resin from a bottom of the mold.

11. The method of any of claims 8 to 10, wherein impregnating the fiber pultrusions with resin comprises: arranging a vacuum bag (820) over the fiber pultrusions and sealing the vacuum bag to the mold surface to define a mold cavity;generating a vacuum in the mold cavity; and supplying resin to the mold cavity.

12. The method of claim 11 , wherein arranging the vacuum bag over the fiber pultrusions comprises arranging the vacuum bag over and around the first guide.

13. The method of claim 12, wherein arranging the vacuum bag over and around the first guide comprises arranging an outlet (840) of the vacuum bag over the first guide.

14. The method of claim 13, wherein the outlet is opposite the mold surface.

15. A method of manufacturing a wind turbine blade, the method comprising: forming (910) an upper blade shell part (100) and a lower blade shell part (200), wherein forming the upper blade shell part and / or the lower blade shell part comprises: arranging the wind turbine blade component of any of claims 1 to 7 on an outer layer laid in a blade shell part mold, wherein arranging the wind turbine blade comprises inserting the wind turbine blade into a cavity defined by a core material (1100); and bonding the wind turbine blade component to the outer layer; joining (920) a reinforcing structure (300) to the upper blade shell part and to the lower blade shell part such that the reinforcing structure is arranged between the upper blade shell part and the lower blade shell part; and joining (930) the upper blade shell part to the lower blade shell part.

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