A wind turbine blade with an aerodynamic component

Abstract

A method for attaching an aerodynamic component to a wind turbine blade body during the manufacturing process. Firstly, a spacer element is attached to either the aerodynamic component or the wind turbine blade body. The aerodynamic component is then arranged at the portion of the blade body, and the first edge of the aerodynamic component is adjusted into a mounting position to minimize the step size between the aerodynamic component and the blade body. The aerodynamic component is temporarily fixed using the spacer element, creating a compartment between the aerodynamic component and the blade body. A first adhesive is injected into this compartment through injection ports in the aerodynamic component, with the spacer element acting as a barrier to prevent the adhesive from leaking out. Finally, the adhesive is allowed to cure, permanently fixing the aerodynamic component in place.

Description

[0001] TITLE

[0002] A WIND TURBINE BLADE WITH AN AERODYNAMIC COMPONENT

[0003] TECHNICAL FIELD

[0004] The present disclosure relates to a prefabricated aerodynamic component for a wind turbine blade and a method of attaching such a component to a body of a wind turbine blade.

[0005] BACKGROUND

[0006] Wind is an increasingly popular clean source of renewable energy with no air or water pollution. When the wind blows, wind turbine blades spin clockwise, capturing energy through a main shaft connected to a gearbox and a generator for producing electricity. Blades of modern wind turbines are carefully designed to maximise efficiency. Modern wind turbine blades may exceed 100 metres in length and 4 metres in width.

[0007] Wind turbine blades are typically made from a fibre-reinforced polymer material, comprising a body with a pressure side shell half and a suction side shell half, also called blade halves. The cross- sectional profile of a typical wind turbine blade includes an airfoil for creating an air flow leading to a pressure difference between both sides. The resulting lift force generates torque for producing electricity.

[0008] As wind turbines increase in size, so do wind turbine blade lengths, resulting in faster tip speeds typically in the range of 75 to 100 metres per second for three-bladed wind turbines. For some two- bladed turbines, the blades can rotate with a tip speed as high as 130 metres per second. This causes very severe erosion conditions at the tip of the blade as well as along the outer third of the leading edge, leading to blade damage in these areas due to the continued impact from wind, rain, hail, sand and / or airborne particles. Such erosive processes can limit the maximum rotational speed of the blades, hence potentially reducing the power output of the wind turbine. These effects are exacerbated by the fact that wind turbines are increasingly subjected to harsh environmental conditions, such as remote offshore sites, mountain regions or other challenging environments.

[0009] Although wind turbine blades are typically expected to last for 20 years, this is often not the case due to the damage caused by erosion of the leading edge necessitating blade repair. Thus, during the lifetime of a wind turbine, considerable resources are expended on continued maintenance operations to ensure optimum turbine performance. However, repair of the leading edge is not easy since it is typically carried out with the blade still mounted on the turbine. This also has significant cost and safety implications, particularly if the wind turbine is located offshore. Leading edge erosion may therefore result in reduced annual energy production and increased need for maintenance and repairs. Today, most wind turbine blades have a joint bonded during manufacturing at the leading edge which is the most aerodynamically sensitive area, especially the outer third of the wind turbine blade. Such a joint introduces both shape irregularities, which degrade performance, and material boundaries which reduce erosion resistance. In order to reduce the damage caused by erosion, it is known to provide a leading-edge component, such as an erosion shield, at the leading edge of a wind turbine blade. A plurality of different types of shields made from different materials exist.

[0010] However, mounting of such a leading-edge component typically requires manual placement by skilled workers as slight mounting misalignments risk causing reduced annual energy production and shorter life spans. However, as the length of wind turbine blades increases so does the length of the leading-edge protection components which become increasingly unwieldy.

[0011] SUMMARY

[0012] On this background, it may be seen as an object of the present disclosure to provide a method of assembling a wind turbine blade comprising a structural blade body and an aerodynamic component with increased precision. Another object of the present disclosure is to provide a aerodynamic component for a wind turbine blade that is easier to mount precisely. One or more of these objects may be met by aspects of the present disclosure as described in the following.

[0013] A first aspect of this disclosure relates to a method of attaching an aerodynamic component to a wind turbine blade body for manufacturing a wind turbine blade, the method comprising the steps of: providing an aerodynamic component comprising a first edge; providing a first spacer element, such as a first bond line, either at or adjacent to the first edge of the aerodynamic component, or on a first side of the wind turbine blade body, wherein the first bond line may optionally be provided as a first double-sided adhesive tape comprising a first adhesive layer at a first side of the first double-sided adhesive tape and a second adhesive layer at an second, opposite, side of the first double-sided adhesive tape and the first adhesive layer of the first double-sided adhesive tape may be attached either at or adjacent to the first edge of the aerodynamic component, or on the first side of the wind turbine blade body; arranging the aerodynamic component at a portion of the wind turbine blade body, such as a recess, a leading portion or a trailing portion of the wind turbine blade body;

[0014] - adjusting the first edge of the aerodynamic component into a mounting position so that a step size between an exterior side of the aerodynamic component and an exterior surface of the wind turbine blade body at the first edge of the aerodynamic component is reduced or minimised; attaching, preferably via the first bond line, for example via the second adhesive layer, the aerodynamic component to the wind turbine blade body so that the first edge of the aerodynamic component is temporarily or detachably attached to the wind turbine blade body in the mounting position and so that a first compartment is formed between the aerodynamic component and the wind turbine blade body; injecting a first adhesive into the first compartment between the aerodynamic component and the wind turbine blade body preferably through one or more injection ports of the aerodynamic component, the one or more injection ports may extend from the exterior, e.g. the exterior side, of the aerodynamic component to the first compartment, wherein the first spacer element acts as an adhesive barrier so as to prevent the first adhesive from exiting the first compartment between the first edge of the aerodynamic component and the wind turbine blade body; and allowing or causing the first adhesive to cure so as to fix the aerodynamic component to the wind turbine blade body in the mounting position and so that the aerodynamic component optionally forms at least part of the exterior surface, such as the leading edge or trailing edge of the wind turbine blade.

[0015] The method of attaching an aerodynamic component to a wind turbine blade body may allow for better alignment, measurement, verification, and correction of the position of the components before they are permanently bonded together. This advantage stems from the use of a temporary fixing step via the first spacer element during the assembly process. Advantageously, by utilizing the first spacer element in the form of a first bond line, the method enables precise alignment of the aerodynamic component to the wind turbine blade body. Initially, the first spacer element is attached either at or adjacent to the first edge of the aerodynamic component or on a first side of the wind turbine blade body. This initial attachment allows for the arrangement of the aerodynamic component at the portion of the wind turbine blade body. Subsequently, the first edge of the aerodynamic component is adjusted into a mounting position, minimizing the step size between the aerodynamic component and the blade body. This adjustment process ensures precise alignment and positioning of the components. Once the aerodynamic component is in the desired mounting position, the bond line is used to temporarily attach the aerodynamic component to the wind turbine blade body. Since the temporary or detachable fixing via the first bond line allows the operators to continually engage and disengage the aerodynamic component, the alignment of the aerodynamic component can be adjusted until assembly tolerances are met. Thus, this allows for further adjustments, measurements, and verifications to be made before the components are permanently bonded.

[0016] The presence of a first compartment between the aerodynamic component and the blade body, created by the spacer element, facilitates the injection of a first adhesive through one or more injection ports of the aerodynamic component. The spacer element acts as an adhesive barrier, preventing the adhesive from exiting the compartment. This containment of the adhesive ensures controlled and precise application, minimizing the risk of unwanted adhesive spreading. Additionally or alternatively, the one or more injection ports may extend through the first spacer element to the first compartment. In other embodiments, the one or more injection ports may be distanced from the first spacer element.

[0017] Once the first adhesive is injected, it is allowed or caused to cure, fixing the aerodynamic component to the wind turbine blade body in the desired mounting position. This curing process ensures a secure and durable bond between the components, resulting in a wind turbine blade with a properly positioned and aligned aerodynamic component.

[0018] By incorporating this method into the manufacturing process, the alignment, measurement, verification, and correction of components are carried out before the adhesive is cured. This approach enables any necessary adjustments or corrections to be made, ensuring that the aerodynamic component is accurately positioned. Consequently, the method reduces the likelihood of mounting misalignments that could result in reduced annual energy production and shorter lifespan of the resulting wind turbine blade.

[0019] Overall, the technical advantage provided by this method is the improved alignment and positioning accuracy in wind turbine blade manufacturing. It allows for precise adjustments and measurements, ensuring optimal component positioning before permanent bonding takes place. This advantage contributes to enhanced overall wind turbine performance, reduced maintenance requirements, and improved operational efficiency.

[0020] Additionally or alternatively, the exterior side of the aerodynamic component may form part of the exterior aerodynamic surface of the wind turbine blade once the aerodynamic component is mounted onto the body. For example, the exterior side of the aerodynamic component may form the leading edge or the trailing edge of the wind turbine blade.

[0021] Additionally or alternatively, the aerodynamic component may be a structural component, e.g. the aerodynamic component may provide load bearing capability to the wind turbine blade. Alternatively, the aerodynamic component may be a fairing component and may thus define part of the exterior surface without providing load bearing capability to the wind turbine blade. In one preferred embodiment, the aerodynamic component is a leading edge fairing.

[0022] Additionally or alternatively, the method may further comprise the steps of:

[0023] - providing a second spacer element, such as a second bond line, either at or adjacent to a second edge of the aerodynamic component, or on a second side of the wind turbine blade body, wherein the second edge of the aerodynamic component is opposite of the first edge, wherein the second bond line may be provided as second double-sided adhesive tape comprising a first adhesive layer at a first side of the second double-sided adhesive tape and a second adhesive layer at an second, opposite, side of the second double-sided adhesive tape and the first adhesive layer of the second double-sided adhesive tape may be attached either at or adjacent to the second edge of the aerodynamic component, or on the second side of the wind turbine blade body;

[0024] - adjusting the second edge of the aerodynamic component into a mounting position so that a step size between the exterior side of the aerodynamic component and the exterior surface of the wind turbine blade body at the second edge of the aerodynamic component is reduced or minimised; and

[0025] - attaching, preferably via the second bond line, for example the second adhesive layer of the second double-sided adhesive tape, the aerodynamic component to the wind turbine blade body so that the second edge of the aerodynamic component is temporarily or detachably attached to wind turbine blade body in the mounting position and so that a second compartment is formed between the aerodynamic component and the wind turbine blade body.

[0026] Similar to the adjustments made with the first edge, the second edge of the aerodynamic component is adjusted into a mounting position, minimizing the step size between the aerodynamic component and the blade body. This adjustment process guarantees that both edges of the aerodynamic component are properly aligned and positioned relative to the wind turbine blade body. Once the second edge of the aerodynamic component is in the desired mounting position, the second bond line is used to temporarily or detachably attach the aerodynamic component to the wind turbine blade body. This temporary or detachable fixing via the second bond line provides increased stability during the assembly process, preventing undesired movements or misalignments of the aerodynamic component, which could negatively impact energy production and blade lifespan. The attachment via the second bond line ensures that the second edge of the aerodynamic component is securely fixed to the wind turbine blade body in the mounting position. This attachment creates a second compartment between the aerodynamic component and the blade body, similar to the previously mentioned first compartment.

[0027] Additionally or alternatively, the first and / or second adhesive(s) may be structural adhesive. This contrasts to the adhesive of the first and / or second bond line which generally comprise(s) or consist(s) of pressure-sensitive adhesives. Furthermore, the first and / or second adhesive(s) may be a low viscosity adhesive and may thus be injectable. Additionally or alternatively, the first side, and optionally the second side, of the wind turbine blade body may be a first side surface and a second side surface, respectively.

[0028] Additionally or alternatively, the first and / or second bond line may be provided as double-sided adhesive tape(s). However, the first and / or second bond line may alternatively each be provided as a single adhesive layer provided in a line.

[0029] In the context of this disclosure, a double-sided adhesive tape may be understood as an elongated backing layer having a first adhesive layer on one side and a second adhesive layer on the opposite side. The exterior side of the first adhesive layer is covered by a first peel layer and the exterior side of the second adhesive layer is covered by a second peel layer. The first and / or second adhesive layer may comprise a pressure sensitive adhesive that may be adapted to form a detachable bond.

[0030] In the context of the present disclosure, a temporary or a detachable attachment of the first and / or second edge of the aerodynamic component may be understood as the attachment being sufficient for maintaining the aerodynamic component in position during manufacturing but would be insufficient to maintain the aerodynamic component in position during operation of the wind turbine blade. Continuing this, a fixation of the aerodynamic component may be understood as a fixing which is sufficient to maintain the aerodynamic component in position during operation, for a large portion of or even for the entirety of the lifetime of the aerodynamic component. The fixing may in some embodiments be reversible, for example using thermoplastic adhesives, to allow the aerodynamic component to be replaced.

[0031] Additionally or alternatively, the second compartment may be separate from the first compartment and wherein the method may further comprise:

[0032] - arranging a first barrier element and a second barrier element between the aerodynamic component and the wind turbine blade body so that the first compartment is bounded or delimited by the first bond line and the first barrier element and the second compartment is bounded or delimited by the second bond line and the second barrier element, wherein the first bond line and the first barrier element act as adhesive barriers so that during injection of the first adhesive, the first adhesive is prevented from exiting the first compartment;

[0033] - injecting a second adhesive into the second compartment preferably through one or more injection ports of the aerodynamic component, the one or more injection ports may extend from the exterior, e.g. the exterior side, of the aerodynamic component to the second compartment, wherein the second spacer element may act as an adhesive barrier so as to prevent the second adhesive from exiting the second compartment between the second edge of the aerodynamic component and the wind turbine blade body. Additionally, the step of allowing or causing the first adhesive to cure may further comprise allowing or causing the second adhesive to cure.

[0034] Accordingly, the second compartment is separate from the first compartment and thus has clear boundaries between them. To enhance the adhesive containment, the method incorporates a first barrier element and a second barrier element between the aerodynamic component and the wind turbine blade body. These barriers are arranged in conjunction with and adjacent to the first and second bond lines, respectively. The presence of the first and second barrier elements enhance the containment of the first and second adhesives within their respective compartments. The first compartment is bounded by the first bond line and the first barrier element, while the second compartment is bounded by the second bond line and the second barrier element. These barriers ensure that the injected adhesives are confined within their designated compartments, reducing or preventing any unwanted mixing or leaking. Additionally or alternatively, the one or more injection ports may extend through the second bond line to the second compartment. In other embodiments, the one or more injection ports may be distanced from the second bond line.

[0035] By employing separate barrier elements and compartments, the method ensures a controlled and contained application of adhesives, minimizing the risk of adhesive leakage or unwanted contact between the adhesives in the compartments. This containment provides a reliable and consistent bonding process, contributing to the overall stability and durability of the aerodynamic component attachment.

[0036] Additionally or alternatively, the first and / or second barrier elements may an open cell foam band and / or may include an adhesive, e.g. pressure-sensitive, on one side. Thus, the barrier elements may be adapted to adhere to either the aerodynamic component or the wind turbine blade body.

[0037] Additionally or alternatively, the injection of the first adhesive and the second adhesive may be performed simultaneously or it may be performed separately, e.g. sequentially. Furthermore, the curing of the first and second adhesives may be performed separately but is preferably performed simultaneously. Since such a unified curing process may ensure that both adhesives solidify simultaneously, promoting uniformity and integrity in the bonding between the aerodynamic component and the wind turbine blade body. The synchronized curing process may enhance the overall structural strength and long-term performance of the wind turbine blade.

[0038] Additionally or alternatively, wherein the first and second barrier elements may define a cavity there in between, which, during injection of the first and second adhesive is not filled with adhesive. Such an air-filled cavity may save weight without substantially compromising the attachment of the aerodynamic component. Additionally or alternatively, the first adhesive may preferably fill the entirety of the first compartment and / or wherein the second adhesive may preferably fill the entirety of the second compartment.

[0039] Additionally or alternatively, the first compartment and the second compartment may together form a single, continuous compartment extending from the first spacer element to the second spacer element, for example from the first bond line to the second bond line.

[0040] By combining the first compartment and the second compartment into a single, continuous compartment, the method may streamline the assembly of the aerodynamic component. This integration eliminates the need to separately handle and manage two distinct compartments, which may reduce complexity and potential errors during the assembly process. If the profile of the aerodynamic component is shaped to match the shape of the portion of the body, the gap formed there in between can be minimized and thus, the additional weight of the cured first adhesive filling the first compartment can be reduced.

[0041] Additionally or alternatively, the first and / or the second bond line may comprise a first peel layer covering an exterior side of a first adhesive layer of the bond line. The method may further comprise a step of removing the first peel layer from the bond line preferably prior to positioning the respective bond line on either the aerodynamic component or wind turbine blade body.

[0042] Additionally or alternatively, the first and / or the second bond line(s) may comprise a second peel layer covering an exterior side of a second adhesive layer of the bond line. The step of providing the first and / or second bond line(s) on either aerodynamic component or wind turbine blade body may include maintaining the second peel layer on the exterior side of the second adhesive layer. The method may further comprise a step of removing the second peel layer of the first and / or second bond line(s) preferably prior to the step of attaching the aerodynamic component to the wind turbine blade in the mounting position.

[0043] The placement of bond line on the aerodynamic component offers an advantage of reducing cycle time through parallel processing. By separating the tasks of blade preparation and bond line attachment, operators can simultaneously work on different stages of the manufacturing process, which may effectively optimise resource utilization and minimises idle time. This streamlined workflow may not only enhance overall efficiency and productivity but may also allow manufacturers to produce more wind turbine blades within a given timeframe, meeting the growing demand for renewable energy.

[0044] Additionally or alternatively, the aerodynamic component may comprise one or more drain holes. During injection of the first adhesive and / or second adhesive, air within the first and / or second compartment may be vented through the one or more drain holes. The inclusion of one or more drain holes in the aerodynamic component may provide a significant advantage by allowing for the venting of air trapped within the compartments during adhesive injection, potentially reducing voids in the adhesives and thus improving bonding quality. By minimizing voids, the structural integrity of the blade is enhanced, which may reduce the risk of delamination and improving long-term performance. Additionally, the efficient removal of air pockets may decrease the likelihood of stress concentration, crack propagation, and moisture ingress, and may thus lead to reduced maintenance requirements and optimized operational lifespan.

[0045] Additionally or alternatively, the first and / or second barrier elements may be adhesive barrier element(s) and / or may be air permeable so that, during injection of the first and / or second adhesive, air within the first and / or second compartment is vented through the respective barrier element before exiting through the one or more drain holes. In other embodiments, the first and / or second barrier element(s) may be air impermeable.

[0046] By providing the barrier elements as air permeable, air can escape from the first and second compartments through the barrier elements e.g. to be vented via the drain holes. Accordingly, the risk of void formation in the cured adhesives is reduced.

[0047] Additionally or alternatively, the aerodynamic component may be supported via a plurality of straps during the step(s) of adjusting the aerodynamic component into the mounting position and / or the step(s) of attaching, via the second adhesive layer, the aerodynamic component to the wind turbine blade body. The straps may in principle be any kind of support, but is advantageously a suspended support.

[0048] Additionally or alternatively, the wind turbine blade body may be provided with the portion facing downwards preferably prior to the step of arranging the aerodynamic component at the portion of the wind turbine blade body.

[0049] Additionally or alternatively, the step(s) of removing the second peel layer may comprise spacing the plurality of straps from the wind turbine blade body, preferably by inserting one or more inserts between the plurality of straps and the wind turbine blade body. By spacing the plurality of straps, it may be easier to access and remove the second peel layer and may reduce the risk of severing the peel layer during removal.

[0050] Additionally or alternatively, the portion of the wind turbine blade body is a recess. The first side, and optionally the second side, of the wind turbine blade body may form part of the recess, such as the floor of the recess. For example, the first side may be delimited by the first spacer element and optionally the first barrier element, and, optionally, the second side may be delimited by the second spacer element and optionally the second barrier element. Additionally or alternatively, the first side, and preferably the second side, of the wind turbine blade body may be parallel to adjacent portions of the exterior surface of the wind turbine blade body, respectively. For example, the first side and preferably the second side may follow the profile of the exterior surface of the wind turbine blade body.

[0051] Additionally or alternatively, the aerodynamic component comprises at least one of a leading edge erosion protection layer, one or more vortex generators, a plurality of serrations, one or more T- spoilers.

[0052] A second aspect of this disclosure relates to a kit of parts for the attachment of an aerodynamic component to a wind turbine blade body of a wind turbine blade, the kit of parts comprising: the aerodynamic component including: o a curved profile having an interior side, an exterior side, a first edge and a second edge, wherein the exterior side of the curved profile is for defining a leading edge or a trailing edge of the wind turbine blade and is preferably substantially U-shaped; o one or more injection ports extending through the curved profile from the exterior side to the interior side, and o preferably one or more drain holes extending through the curved profile from the exterior side to the interior side;

[0053] - a first spacer element, such as a first bond line, e.g. a first double-sided adhesive tape, configured for being attached to the interior side of the aerodynamic component at or adjacent to the first edge of the aerodynamic component; and preferably a second spacer element, such as a second bond line, e.g. a double-sided adhesive tape, configured for being attached to the interior side of the aerodynamic component at or adjacent to the second edge of the aerodynamic component;

[0054] Additionally or alternatively, the kit of parts may further comprise: a first barrier element configured for being attached on the interior side of the aerodynamic component adjacent to the first bond line so as to define a boundary of a first area of the interior side of the aerodynamic component, wherein the first area forms part of a first compartment when the aerodynamic component is attached to the wind turbine blade body; and / or a second barrier element configured for being attached on the interior side of the aerodynamic component adjacent to the second bond line so as to define a boundary of a second area of the interior side of the aerodynamic component, wherein the second area forms part of a second compartment when the aerodynamic component is attached to the wind turbine blade body. A third aspect of this disclosure relates to a wind turbine blade, comprising: a body including a portion, e.g. a recess, a trailing portion or a leading portion, with a first side and a second side, optionally wherein the first side is on a pressure or suction side of the wind turbine blade and the second side is on the opposite side of the first side; an aerodynamic component comprising a first edge and a second edge, the first edge being attached to the first side of the body and the second edge being attached to the second side of the body; a first spacer element, such as a first bond line, arranged between the first side of the body and the aerodynamic component adjacent to the first edge, preferably the first bond line adheres the first side of the body to the aerodynamic component adjacent to the first edge; preferably a second spacer element, such as a second bond line, arranged between the second side of the body and the aerodynamic component adjacent to the second edge, preferably the second bond line adheres the second side of the body to the aerodynamic component adjacent to the second edge; and a cured first adhesive fixing the aerodynamic component to body so that the aerodynamic component either covers the portion of the body, e.g. the recess, the leading portion or the trailing portion and may thus define part of the exterior surface, such as a leading edge or a trailing edge of the wind turbine blade.

[0055] Additionally or alternatively, the body and the aerodynamic component may extend along a longitudinal course from a root to a tip. The body and the aerodynamic component may comprise a root region (30) and an airfoil region with the tip. The body and the aerodynamic component may comprise a chord line extending between a leading edge of the aerodynamic component and a trailing edge of the body. The body and the aerodynamic component may comprise an aerodynamic exterior blade surface which includes the pressure side and the suction side. The pressure and suction sides may be partly formed by the body and partly by the aerodynamic component.

[0056] Additionally or alternatively, the wind turbine blade may further comprise: a first barrier element arranged between the aerodynamic component and the first side of the body, wherein the cured first adhesive at least partly, preferably entirely, fills a first compartment extending from the first spacer element to the first barrier element between the aerodynamic component and the first side of the body; preferably a second barrier element arranged between the aerodynamic component and the first side of the body, wherein a cured second adhesive at least partly, preferably entirely, fills a second compartment extending from the second spacer element to the second barrier element between the aerodynamic component and the second side of the body; and preferably a cavity extending from the first barrier element to the second barrier element and between the portion of the body and the aerodynamic component.

[0057] The barrier element(s) may provide the advantage of preventing filling the entire compartment between the body and aerodynamic component and between the spacer elements with adhesive and may thus reduce the weight of the wind turbine blade.

[0058] Additionally or alternatively, the cavity may be air-filled. The aerodynamic component may comprise one or more drain holes extending through the aerodynamic component preferably to the cavity. The drain holes are adapted to allow drainage of condensation within the aerodynamic component, e.g. the cavity.

[0059] Additionally or alternatively, the first and / or second barrier element may be air permeable preferably so as to allow air from the first and / or second compartment to vent through the first and / or second barrier element, respectively, during infusion of the first and / or second adhesive, respectively.

[0060] A fourth aspect of this disclosure relates to a wind turbine blade, preferably according to the third aspect, which is obtainable by a method according to the first aspect.

[0061] A person skilled in the art will appreciate that any one or more of the above aspects of this disclosure and embodiments thereof may be combined with any one or more of the other aspects of this disclosure and embodiments thereof.

[0062] BRIEF DESCRIPTION OF THE DRAWINGS

[0063] Embodiments of this disclosure will be described in more detail in the following with regard to the accompanying figures. The figures show one way of implementing the present invention and are not to be construed as being limiting to other possible embodiments falling within the scope of the attached claim set.

[0064] Fig. 1 is a schematic perspective view of a wind turbine.

[0065] Fig. 2 is a schematic perspective view of a wind turbine blade for a wind turbine as shown in Fig. 1.

[0066] Fig. 3 is a schematic cross-sectional view of an aerodynamic component prior to being attached to a wind turbine blade body.

[0067] Fig. 4 is a schematic cross-sectional view of a double-sided adhesive tape for use in assembling the aerodynamic component and the wind turbine blade body of Fig. 3.

[0068] Fig. 5 is a schematic perspective view of a longitudinal section of the aerodynamic component and the wind turbine blade body during assembly thereof. For illustrative purposes, the longitudinal section has been cut out from the remainder of the aerodynamic component and the wind turbine blade body.

[0069] Fig. 6 is a schematic cross-sectional view similar to Fig. 4 showing the aerodynamic component attached to the wind turbine blade body.

[0070] Fig. 7 is a is a schematic cross-sectional view of an aerodynamic component according to another embodiment attached to the wind turbine blade body.

[0071] DETAILED DESCRIPTION

[0072] In the following figure description, the same reference numbers refer to the same or similar elements and may thus not be described in relation to all figures.

[0073] Fig. 1 illustrates a conventional modern upwind wind turbine 2 according to the so-called "Danish concept" with a tower 4, a nacelle 6 and a rotor with a substantially horizontal rotor shaft which may include a tilt angle of a few degrees. The rotor includes a hub 8 and three blades 10 extending radially from the hub 8, each having a blade root 16 nearest the hub and a blade tip 14 furthest from the hub 8.

[0074] Fig. 2 shows a schematic view of an exemplary wind turbine blade 10. The wind turbine blade 10 has the shape of a conventional wind turbine blade with a root end 17 and a tip end 15 and comprises an exterior surface 27 defining a root region 30 closest to the hub, a profiled or an airfoil region 34 furthest away from the hub and a transition region 32 between the root region 30 and the airfoil region 34. The blade 10 comprises a leading edge 18 facing the direction of rotation of the blade 10, when the blade is mounted on the hub 8, and a trailing edge 20 facing the opposite direction of the leading edge 18. The blade 10 comprises a body 13 and an aerodynamic component 40 attached to an outer third of the wind turbine blade in the tip region 34 but may have a shorter or greater longitudinal extent, for example the aerodynamic component may extend in the entire airfoil region 34 as well or even along the entire length of the wind turbine blade 10. In the shown example, the leading edge 18 is partly defined by the body 13, i.e. in the innermost two thirds of the blade length, and partly by the aerodynamic component 40, i.e. in the outermost third of the blade length. In other embodiments, the aerodynamic component 40 may define part of the trailing edge.

[0075] The airfoil region 34 (also called the profiled region) has an ideal or almost ideal blade shape with respect to generating lift, whereas the root region 30 due to structural considerations has a substantially circular or elliptical cross-section, which for instance makes it easier and safer to mount the blade 10 to the hub. The diameter (or the chord) of the root region 30 may be constant along the entire root region 30. The transition region 32 has a transitional profile gradually changing from the circular or elliptical shape of the root region 30 to the airfoil profile of the airfoil region 34. The chord length of the transition region 32 typically increases with increasing distance r from the hub. The airfoil region 34 has an airfoil profile with a chord extending between the leading edge 18 and the trailing edge 20 of the blade 10. The width of the chord decreases with increasing distance r from the hub. A shoulder 38 of the blade 10 is defined as the position, where the blade 10 has its largest chord length. The shoulder 38 is typically provided at the boundary between the transition region 32 and the airfoil region 34.

[0076] It should be noted that the chords of different sections of the blade normally do not lie In a common plane, since the blade may be twisted and / or curved (i.e. pre-bent), thus providing the chord plane with a correspondingly twisted and / or curved course, this being most often the case in order to compensate for the local velocity of the blade being dependent on the radius from the hub.

[0077] Turning to Fig. 3, an initial step in the method of attaching the aerodynamic component 40 to a body 13 is shown. The aerodynamic component 40 has a curved profile 41, which is generally U- shaped, which terminates at a first edge 42 and at a second edge 42' opposite of the first edge 42. The aerodynamic component defines an interior side 44, which is intended to face the body 13, and an exterior side 45, which is intended to define part of the exterior surface 27 of the blade 10. The aerodynamic component 40 has been prepared by attaching a first spacer element 60 implemented here as a first bond line in the form of a first double-sided adhesive tape 60, to the interior side 44 adjacent to the first edge 42 and by attaching a second spacer element 60' implemented here as a second bond line in the form of a second double-sided adhesive tape 60', to the interior side 44 adjacent to the second edge 42'. Furthermore, a first barrier element 66 has been attached to the interior side 44 adjacent to but distanced from the first double-sided adhesive tape 60 thus defining a first area 48 there in between. Likewise, a second barrier element 66' has been attached to the interior side 44 adjacent to but distanced from the second double-sided adhesive tape 60' thus defining a second area 48' there in between. The barrier elements 66, 66' are an open cell foam band including an adhesive, e.g. pressure-sensitive, on one side. The aerodynamic component 40 is provided with injection ports 46, 46' extending from the exterior side 45 to the interior side 44 both within the first area 48 and the second area 48'. The body 13 of the wind turbine blade 10 (which is best seen in Fig. 2) provides the structural strength of the wind turbine blade 10. The body 13 comprises a portion 19 with a first side 21 on the pressure side 22 and a second side 23 on the suction side 24. The body 13 can further comprise a vent hole 28 for venting e.g. condensation within the body 13 as shown. In the present example, the portion 19 is a leading portion but may in other embodiments for example be a trailing portion. The leading portion 19 is intended to be covered by the aerodynamic component 40. The body 13 also defines part of the exterior surface 27 of the wind turbine blade. The double-sided adhesive tapes 60, 60' and / or the barrier elements 66, 66' could alternatively be placed on the first and second sides 21, 23 of the body 13, respectively. The first and second double-sided adhesive tape 60, 60' is shown in greater detail in Fig. 4. Each double-sided adhesive tape 60, 60' comprises a layered structure with a backing layer 61, 61' forming the middle layer and sandwiched between a first adhesive layer 62, 62' and a second adhesive layer 64, 64'. A first peel layer 63, 63' covers the exterior side of the first adhesive layer 62, 62' and a second peel layer 65, 65' covers the exterior side of the second adhesive layer 64, 64'. The first peel layer 63, 63' is removed prior to attaching to the aerodynamic component 40 to arrive at the arrangement as shown in Fig. 3.

[0078] Once the aerodynamic component 40 and the body 13 have been provided as shown in Fig. 3, the aerodynamic component 40 is moved into an initial mounting position and supported by a plurality of straps 68 which is best seen in Fig. 5. The straps 68 could be replaced by any kind of suitable support, especially a suspended support, which allow relative adjustment between the aerodynamic component 40 and the body 13. Fig. 5 shows a single longitudinal section of the aerodynamic component 40 and the body 13 but it will be appreciated that the same approach applies to the remainder of the aerodynamic component 40. Fig. 5 illustrates that an insert 69 is inserted between the strap 68 and the suction side 24 of the body 13 (a similar insert is also inserted between the strap 68 and the pressure side 22 of the body 13 but this is not shown in Fig. 5). However, initially, such inserts 69 can be omitted to allow operators to align the aerodynamic component 40 on the body 13. Once sufficiently supported by the straps 68, the operators proceed to adjust and align the first edge 42 of the aerodynamic component 40 into a mounting position as shown in Figs. 5-6 so that a step size 43 (best seen in Fig. 6) between an exterior side 45 of the aerodynamic component 40 and an exterior surface 27 of the wind turbine blade body 13 (i.e. on the pressure side 22) at the first edge 42 of the aerodynamic component 40 is reduced or minimised. Likewise, the second edge 42' of the aerodynamic component 40 is adjusted and aligned into the mounting position as shown in Figs. 5-6 so that a step size 43' (best seen in Fig. 6) between an exterior side 45 of the aerodynamic component 40 and an exterior surface 27 of the wind turbine blade body 13 (i.e. on the suction side 24) at the second edge 42' of the aerodynamic component 40 is also reduced or minimised. While the aerodynamic component 40 is supported in place by the straps and thus not attached, the operators can measure the position and orientation of the aerodynamic component 40 to ensure that assembly specifications are met. Inserts 69 are then inserted between the straps 68 and the exterior surface 27 of the body 13 as shown in Fig. 5. Thus, access is provided to the second peel layer 65, 65' still present on the double-sided adhesive tapes 60, 60' (although this is not shown in Figs. 5-6). The operators then proceed to carefully remove the second peel layers 65, 65'. Once removed, the exterior side 45 of the aerodynamic component 40 is pushed so that the second adhesive layers 64, 64' contact and adhere to the leading portion 19 of the body 13. Thus, the double-sided adhesive tapes 60, 60' temporarily attach the aerodynamic component 40 to the body 13 and a first and a second compartment 50, 50' is defined between the interior side 44 of the aerodynamic component 40 and the first and second side 21, 23 of the body 13, respectively. The first compartment 50 is bounded by the first double-sided adhesive tape 60 and the first barrier element 66. The second compartment 50' is bounded by the first double-sided adhesive tape 60' and the second barrier element 66. The operators can then verify the position of the aerodynamic component 40, e.g. by inspecting that the step sizes 43, 43' are within design tolerances. If not satisfactory, the aerodynamic component 40 can be easily detached from the body 13 by pulling the first and / or second edges 42, 42', and adjusted until the position is satisfactory. The aerodynamic component 40 is then easily reattached by pushing exterior side 45 so that the double-sided adhesive tapes 60, 60' adhere again to the body 13.

[0079] Turning to Fig. 6, once the position of the aerodynamic component 40 is satisfactory, a first adhesive 52 is injected through injection ports 46 (best seen in Figs. 3 and 6) to fill the first compartment 50 and a second adhesive 52' is injected through injection ports 46' (best seen in Figs. 3 and 5-6) to fill the second compartment 50'. The first and second adhesives 52, 52' are relatively low viscosity structural adhesives, for example epoxy, vinyl ester, methyl methacrylate (MMA), or polyester. The double-sided adhesive tapes 60, 60' and barrier elements 66, 66' prevent the first and second adhesives 52, 52' from exiting their respective compartments 50, 50'. Furthermore, the barrier elements 66, 66' are air permeable while the double-sided adhesive tapes 60, 60' are generally air impermeable. Thus, during injection of the adhesives 52, 52', air exits the compartments 50, 50' through the barrier elements 66, 66' into a cavity 51 which is defined between the interior side 44 of the aerodynamic component 40 and the leading portion 19 of the body 13 and which is bounded by the barrier elements 66, 66'. Thus, pressure within the cavity 51 increases during infusion but the aerodynamic component 40 is provided with drain holes 47 which extend from the exterior side 45 to the cavity 51 and which allow the build-up of air in the cavity 51 to vent through these drain holes 47. The drain holes 47 also function as a drainage for condensation build up in the cavity 51 during operation of the blade 10. Once the compartments are sufficiently filled, e.g. entirely, the adhesives 52, 52' cure and exhibit a very low void and defect fraction due to the air permeability of the barrier elements 66, 66'. Thus, the aerodynamic component 40 is fixed to the body 13 so that the aerodynamic component 40 forms at least part of the leading edge 18 of the wind turbine blade 10 as best seen in Fig. 2. In a post processing step, any gap between the first and second edges 42, 42' is filled with sealant 67, 67' to ensure a smooth transition of the exterior surface 27 between the body 13 and the aerodynamic component 40. In another embodiment (which is not shown), the barrier elements 66, 66' are omitted and thus the first and second compartments 50, 50' form a single, continuous compartment. In such an embodiment, the interior side 44 and the leading portion 19 are advantageously shaped to substantially match each other since the entirety of the space there in between is filled with the adhesives 52, 52'. Turning to Fig. 7, a different embodiment is shown. In this embodiment, the portion of the body 13 comprises a recess formed in the exterior surface 27 of the wind turbine blade. In contrast to the embodiment shown in Fig. 3, the first side 21 and the second side 23 form part of the floor of the recess. The first and second side 21, 23 define respective surfaces which are parallel (but offset inwardly) to parts of the final exterior surface of the wind turbine blade. This allows for absorbing positioning tolerances when placing the aerodynamic component 40 without compromising evenness of the exterior surface. Two spacer elements 60, 60' are attached to the first and second side 21, 23 respectively. The spacer elements may alternatively be implemented as bond lines 60, 60' as described above. The aerodynamic component 40 is, in this embodiment, shown as a flat piece and may, for example, comprise one or more vortex generators or one or more T-spoilers. The aerodynamic component 40 could also be a flat part of the leading-edge protection component having parallel exterior surface. Also, the recess may continue further from the aerodynamic component 40 to accommodate one or more further components. For example, the transition from the second side 23 of the recess to the exterior surface 27 at the sealant 67' may be further distanced from the aerodynamic component 40 to accommodate these further components. The first edge 42 and the second edge 42' of the aerodynamic component are detachably attached to the first spacer element 60 and second spacer element 60', respectively so as to form a single continuous compartment 50 delimited by the floor of the recess, the spacer elements 60, 60' and an interior side of the aerodynamic component 40. The first side 21 and the second side 23 are arranged in parallel to adjacent portions of the exterior surface 27, respectively. This allows an operator to easier align the aerodynamic component 40 in a flush arrangement with the exterior surface 27 to reduce or minimise detrimental aerodynamic effects. Once the alignment meets the associated manufacturing tolerance, an adhesive 52 can be injected, e.g. via one or more injection holes (not shown) of the aerodynamic component 50. Air within the compartment 50 prior to adhesive injection can be vented e.g. a vent hole (not shown). The transition between the exterior surface 27 and the first edge 42 and second edge 42' is filled with a sealant 67, 67' (or filler material) to ensure a smooth transition of the exterior surface 27 between the body 13 and the aerodynamic component 40. The sealant 67, 67' may have a lower elastic modulus than the adhesive 52, 52'.

[0080] LIST OF REFERENCES

[0081] 2 wind turbine 50 first compartment

[0082] 4 tower 50' second compartment

[0083] 6 nacelle 51 cavity

[0084] 8 hub 52 first adhesive

[0085] 10 blade 40 52' second adhesive

[0086] 13 body 60 first spacer element

[0087] 14 blade tip 61 backing layer

[0088] 15 tip end 62 first adhesive layer

[0089] 16 blade root 63 first peel layer

[0090] 17 root end 45 64 second adhesive layer

[0091] 18 leading edge 65 second peel layer

[0092] 19 leading portion 60' second spacer element

[0093] 20 trailing edge 66 first barrier element

[0094] 21 first side 66' second barrier element

[0095] 22 pressure side 50 67, 67' sealant

[0096] 23 second side 68 strap

[0097] 24 suction side 69 insert

[0098] TJ exterior surface L longitudinal axis

[0099] 28 vent hole

[0100] 30 root region

[0101] 32 transition region

[0102] 34 airfoil region

[0103] 36 tip region

[0104] 38 shoulder

[0105] 40 aerodynamic component

[0106] 41 profile

[0107] 42 first edge

[0108] 42' second edge

[0109] 43, 43' step size

[0110] 44 interior side

[0111] 45 exterior side

[0112] 46, 46' injection port

[0113] 47 drain hole

[0114] 48 first area

[0115] 48' second area

Claims

CLAIMS1. A method of attaching an aerodynamic component to a wind turbine blade body for manufacturing a wind turbine blade, the method comprising the steps of:- providing an aerodynamic component comprising a first edge;- providing a first spacer element, such as a first bond line, either at or adjacent to the first edge of the aerodynamic component, or on a first side of the wind turbine blade body;- arranging the aerodynamic component at a portion of the wind turbine blade body, such as a recess, a leading portion or a trailing portion of the wind turbine blade body;- adjusting the first edge of the aerodynamic component into a mounting position so that a step size between an exterior side of the aerodynamic component and an exterior surface of the wind turbine blade body at the first edge of the aerodynamic component is reduced or minimised;- attaching, preferably via the first spacer element or the first bond line, the aerodynamic component to the wind turbine blade body so that the first edge of the aerodynamic component is detachably attached to the wind turbine blade body in the mounting position and so that a first compartment is formed between the aerodynamic component and the wind turbine blade body;- injecting a first adhesive into the first compartment, preferably through one or more injection ports of the aerodynamic component, wherein the first spacer element optionally acts as an adhesive barrier so as to prevent the first adhesive from exiting the first compartment between the first edge of the aerodynamic component and the wind turbine blade body; and- allowing or causing the first adhesive to cure so as to fix the aerodynamic component to the wind turbine blade body in the mounting position.

2. A method according to any one of the previous claims, further comprising the steps of:- providing a second spacer element, such as a second bond line, either at or adjacent to a second edge of the aerodynamic component, or on a second side of the wind turbine blade body, wherein the second edge of the aerodynamic component is opposite of the first edge;- adjusting the second edge of the aerodynamic component into a mounting position so that a step size between the exterior side of the aerodynamic component and the exterior surface of the wind turbine blade body at the second edge of the aerodynamic component is reduced or minimised; and- attaching, preferably via the second spacer element or the second bond line, the aerodynamic component to the wind turbine blade body so that the second edge of the aerodynamic component is detachably attached to wind turbine blade body in the mounting position and so that a second compartment is formed between the aerodynamic component and the wind turbine blade body.

3. A method according to claim 2, wherein the second compartment is separate from the first compartment and wherein the method further comprises:- arranging a first barrier element and a second barrier element between the aerodynamic component and the wind turbine blade body so that the first compartment is bounded by the first bond line and the first barrier element, and the second compartment is bounded by the second bond line and the second barrier element, wherein the first bond line and the first barrier element act as adhesive barriers so that during injection of the first adhesive, the first adhesive is prevented from exiting the first compartment;- injecting a second adhesive into the second compartment preferably through one or more injection ports of the aerodynamic component, wherein the second spacer element optionally acts as an adhesive barrier so as to prevent the second adhesive from exiting the second compartment between the second edge of the aerodynamic component and the wind turbine blade body; and- wherein the step of allowing or causing the first adhesive to cure further comprises allowing or causing the second adhesive to cure.

4. A method according to claim 3, wherein the first and second barrier elements are air permeable so that, during injection of the first and / or second adhesive, air within the first and / or second compartment is vented through the respective barrier element.

5. A method according to claim 2, wherein the first compartment and the second compartment together form a single, continuous compartment extending from the first spacer element to the second spacer element.

6. A method according to any one of the previous claims, wherein the first and / or the second bond line comprises a first peel layer covering an exterior side of a first adhesive layer of the bond line, wherein the method comprises a step of removing the first peel layer from the bond line preferably prior to positioning the respective bond line on either the aerodynamic component or wind turbine blade body.

7. A method according to any one of the previous claims, wherein the first and / or the second bond line(s) comprises a second peel layer covering an exterior side of a second adhesivelayer of the bond line, wherein the step of positioning the first and / or second bond line(s) on either aerodynamic component or wind turbine blade body includes maintaining the second peel layer on the exterior side of a second adhesive layer, wherein the method further comprises a step of removing the second peel layer of the first and / or second bond line preferably prior to the step of attaching the aerodynamic component to the wind turbine blade in the mounting position.

8. A method according to any one of the previous claims, wherein the aerodynamic component comprises one or more drain holes, wherein during injection of the first adhesive and / or second adhesive, air within the first and / or second compartment is vented through the one or more drain holes.

9. A method according to any one of the previous claims, wherein the aerodynamic component is supported via a plurality of straps during the step(s) of adjusting the aerodynamic component into the mounting position and the step(s) of attaching, via the second adhesive layer, the aerodynamic component to the wind turbine blade body.

10. A method according to claims 7 and 9, wherein the step(s) of removing the second peel layer comprises spacing the plurality of straps from the wind turbine blade body, preferably by inserting one or more inserts between the plurality of straps and the wind turbine blade body.

11. A method according to any one of the previous claims, wherein the portion of the wind turbine blade body is a recess, and wherein the first side, and optionally the second side, of the wind turbine blade body forms part of the recess, and, optionally, wherein the first side, and preferably the second side, of the wind turbine blade body are parallel to adjacent portions of the exterior surface of the wind turbine blade body, respectively.

12. A kit of parts for the attachment of an aerodynamic component to a wind turbine blade body of a wind turbine blade, the kit of parts comprising: the aerodynamic component including o a curved profile having an interior side, an exterior side, a first edge and a second edge, wherein the exterior side of the curved profile is for defining a leading edge of the wind turbine blade and is preferably substantially U-shaped; o one or more injection ports extending through the curved profile from the exterior side to the interior side, and o preferably one or more drain holes extending through the curved profile from the exterior side to the interior side;a first spacer element, such as a first bond line, configured for being attached to the interior side of the aerodynamic component at or adjacent to the first edge; preferably a second spacer element, such as a second bond line, configured for being attached to the interior side of the aerodynamic component at or adjacent to the second edge;13. A kit of parts according to claim 12, further comprising: a first barrier element configured for being attached on the interior side of the aerodynamic component adjacent to the first spacer element so as to define a boundary of a first area of the interior side of the aerodynamic component, wherein the first area forms part of a first compartment when the aerodynamic component is attached to the wind turbine blade body; and / or a second barrier element configured for being attached on the interior side of the aerodynamic component adjacent to the second spacer element so as to define a boundary of a second area of the interior side of the aerodynamic component, wherein the second area forms part of a second compartment when the aerodynamic component is attached to the wind turbine blade body.

14. A wind turbine blade comprising: a body including a portion with a first side and a second side, optionally wherein the first side is on a pressure or suction side of the wind turbine blade and the second side is on the opposite side of the first side; an aerodynamic component comprising a first edge and a second edge, the first edge being attached to the first side of the body and the second edge being attached to the second side of the body; a first spacer element, such as a bond line, between the first side of the body and the aerodynamic component adjacent to the first edge; preferably a second spacer element, such as a second bond line, between the second side of the body and the aerodynamic component adjacent to the second edge, wherein the second bond line preferably adheres the second side of the body to the aerodynamic component adjacent to the second edge; and a cured first adhesive fixing the aerodynamic component to body so that the aerodynamic component covers the portion of the body.

15. A wind turbine blade according to claim 14 further comprising:A first barrier element arranged between the aerodynamic component and the first side of the body, wherein the cured first adhesive at least partly, preferably entirely, fills a first compartment extending from the first spacer element, such as the first bond line,to the first barrier element between the aerodynamic component and the first side of the body; preferably a second barrier element arranged between the aerodynamic component and the first side of the body, wherein a cured second adhesive at least partly, preferably entirely, fills a second compartment extending from the second spacer element, such as the second bond line, to the second barrier element between the aerodynamic component and the second side of the body; and preferably a cavity extending from the first barrier element to the second barrier element and between the portion of the body and the aerodynamic component; wherein the first and / or second barrier element(s) is / are optionally air permeable preferably so as to allow air from the first and / or second compartment to vent through the first and / or second barrier element(s), respectively, during injection of the first and / or second adhesive, respectively.

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