WO2012028615A2 - Wind turbine blade - Google Patents

Wind turbine blade Download PDF

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Publication number
WO2012028615A2
WO2012028615A2 PCT/EP2011/064907 EP2011064907W WO2012028615A2 WO 2012028615 A2 WO2012028615 A2 WO 2012028615A2 EP 2011064907 W EP2011064907 W EP 2011064907W WO 2012028615 A2 WO2012028615 A2 WO 2012028615A2
Authority
WO
WIPO (PCT)
Prior art keywords
main body
core
turbine blade
wind turbine
center
Prior art date
Application number
PCT/EP2011/064907
Other languages
French (fr)
Other versions
WO2012028615A3 (en
Inventor
Joseba Palacio Argüelles
José Ignacio MARTÍN FERNANDEZ
Juan Carlos AUSÍN CALVO
Original Assignee
Batz, S.Coop.
Ennera Energy And Mobility, S.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Batz, S.Coop., Ennera Energy And Mobility, S.L. filed Critical Batz, S.Coop.
Publication of WO2012028615A2 publication Critical patent/WO2012028615A2/en
Publication of WO2012028615A3 publication Critical patent/WO2012028615A3/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14008—Inserting articles into the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/065—Rotors characterised by their construction elements
    • F03D1/0675—Rotors characterised by their construction elements of the blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0078—Measures or configurations for obtaining anchoring effects in the contact areas between layers
    • B29C37/0082—Mechanical anchoring
    • B29C37/0085—Mechanical anchoring by means of openings in the layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082—Blades, e.g. for helicopters
    • B29L2031/085—Wind turbine blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2240/00—Components
    • F05B2240/20—Rotors
    • F05B2240/21—Rotors for wind turbines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2240/00—Components
    • F05B2240/20—Rotors
    • F05B2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/10—Inorganic materials, e.g. metals
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/20—Inorganic materials, e.g. non-metallic materials
    • F05B2280/2001—Glass
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/20—Inorganic materials, e.g. non-metallic materials
    • F05B2280/2006—Carbon, e.g. graphite
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/40—Organic materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/40—Organic materials
    • F05B2280/4003—Synthetic polymers, e.g. plastics
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • This invention relates to wind turbine blades and the method for their manufacture.
  • Patent application WO2010025830 discloses a wind turbine blade that comprises a main body formed by two or more connected sections, each one of which comprises at least one final area of thermoplastic material, said areas of adjacent sections being welded in their connection.
  • the sections are shells formed by a polymer material, preferably epoxy resin, in their bodies and by thermoplastic material in their end zones, and are connected all the way along the blade.
  • the sections In their interior the sections have a core, which is a longitudinal reinforcement in the form of a quadrangular beam, formed by a fibre-reinforced epoxy resin and which is fixed to the main body.
  • the method for connecting the adjacent sections comprises the connection of the thermoplastic end zones, their heating and fusion through different procedures, pressure in order to weld the connection and cooling.
  • the wind turbine blade comprises a main body that houses in its interior a core to which is fixed said main body; the core comprises a center made of metal or another material of similar characteristics, and the main body is a piece of reinforced plastic moulded on said core.
  • a wind turbine blade is obtained by forming a solid piece with great structural rigidity.
  • the connection between the core and the body is a mechanical connection that prevents welds or gluing.
  • Figure 1 shows a view of the core of an embodiment of the wind turbine blade of the invention.
  • Figure 2 shows a view of the center of the core of Figure 1.
  • Figure 3 shows a view of the support of the core of Figure 1.
  • Figure 4 shows a view of an embodiment of the wind turbine blade of the invention.
  • Figure 5 shows a cross-section of the wind turbine blade with the center of the core of Figure 4.
  • Figure 6 shows another cross-section of the wind turbine blade with the center and the support of the core of Figure 4.
  • Figure 7 shows a cross-section of a semi-mould of an injection mould with the first semi-body of the main body in the cavity showing the mechanical connection between body and core.
  • Figure 8 shows an injection mould with two cavities.
  • Figure 9 shows an injection mould of one cavity showing the moving means.
  • Figures 1 to 3 show the pieces that form the core 1 of the wind turbine blade 4 according to one embodiment.
  • the core 1 is formed by the connection of a center 2 and a support 3.
  • the center 2 is a piece made of metal or another material of similar characteristics, preferably a stamped steel plate, which has a warped section on one part of its length to form a piece in the form of a thin sheet, and disposed with a series of inserts and holes that reinforce the rigidity of the piece and enable the flow of the reinforced plastic between the faces of the center 2, increasing the pressure between the center 2 and the plastic, and making the mechanical connection of the pieces easier.
  • the support 3 is a piece made of metal or another material of similar characteristics, preferably a stamped steel plate that is connected at one end to the center 2 in different alternative forms, by welding, screwing or crimping. The other end of the support is connected to the wind turbine.
  • the center 2 is a piece of fibre-reinforced plastic material, preferably thermostable or thermoplastic.
  • Figures 4 to 6 show the wind turbine blade 4 according to one embodiment.
  • the wind turbine blade 4 is formed by a core 1 and a main body 5.
  • the main body 5 is a piece of fiber-reinforced plastic, preferably fiberglass- reinforced polypropylene.
  • the plastic material of the main body 5 is thermostable or thermoplastic and fiber- reinforced, such as BMC.
  • the fiberglass is mixed inside the flow of the plastic material, and is distributed with it all along the extension of the main body 5 in different directions.
  • the fibres that reinforce the plastic material that forms the main body 5 or the center 2 are natural fibres, carbon nanotubes or another type of nano reinforcement.
  • the method for manufacturing the wind turbine blade 4, based on a preformed core 1 is a moulding process.
  • This moulding process is by injection or compression, the preferred embodiment being formed by an injection process, preferably by the injection of high-pressure long fibre, known as IMC.
  • Figure 7 shows a cross-section of a semi-mould 7 of an injection mould 8, with the first semi-body 11 of the main body 5 obtained with the method for manufacturing a wind turbine blade 4, formed by high-pressure injection.
  • This method comprises two stages: in the first the pre-formed core 1 is placed in a cavity 6 of a semi-mould 7 of an injection mould 8, with the assistance of manual or automatic means. It is supported substantially on one of its faces to prevent it from deforming, and is held with means such as magnets, hooks or similar means.
  • a series of holes 9 of the core 1 coincide with holes or recesses of the semi-mould 10 where the core 1 is supported.
  • the plastic material reinforced with fibres, mixed with it beforehand, is injected on the face that is not supported and a first semi-body 1 1 of the main body 5 connected to the core 1 is obtained.
  • the plastic material runs between the faces of the core 1 , flowing through the holes 9, and filling the holes or recesses of the top semi-mould 10, connecting the first semi-body 1 1 and the core 1 mechanically as it increases the pressure between them.
  • Figure 8 shows an injection mould 8 of two cavities, used to perform the high- pressure injection process in two stages, according to the method for manufacturing a wind turbine blade 4 in a preferred embodiment.
  • the first stage of the method is performed in the first cavity 6, and the second stage in the second cavity 13, for which purpose the unit formed by the first semi-body 11 and the core 1 of the first cavity 6 is removed beforehand, with the assistance of manual or automatic means, and then turned round and placed in the cavity 13, with the complete wind turbine blade 4 being completed in one injection.
  • the first injection of the manufacturing process only a unit formed by the first semi-body 11 and the core 1 is obtained, although from the second injection and in each successive injection a core 1 is placed in the first cavity 6 and a semi-body 1 1 and core 1 unit in the second cavity 13.
  • the injection mould 8 is closed and with one injection a semi-body 1 1 and core 1 unit is obtained from the first cavity 6 and a complete wind turbine blade 4 from the second cavity 13.
  • Figure 9 shows a one cavity injection mould 8, used to perform the high- pressure injection process in two stages, according to the method for manufacturing a wind turbine blade 4 in another embodiment.
  • the two stages of the method are performed in the same cavity 6, and for this purpose in the first injection of the process the core 1 is supported substantially on one of its faces, to prevent it from deforming, on moving means 14 situated in the semi-mould 10.
  • the fiber-reinforced plastic material is injected on the free face and a first semi-body 1 1 of the main body 5 connected to the core 1 is obtained.
  • the moving means 14 are removed and fiber-reinforced plastic material is injected on the free face of the unit formed by the semi-body 11 and the core 1 , a second semi-body 12 of the main body 5 connected to the preceding unit being obtained, and a complete wind turbine blade 4 thereby being created.
  • a complete blade 4 is obtained in a double injection.
  • a cooling time inside the mould 8 is necessary so that the plastic material can cool, as it is injected at a high temperature. This cooling time is determined by the thickness of the piece, among other parameters.
  • the method for manufacturing the wind turbine blade 4 based on a core 1 has alternative final phases such as the deburring of the piece, required until the moulding process in refined, and the painting of the piece in accordance with customer requirements.
  • a wind turbine blade that has a core 1 surrounded by a main body 5 of fiber-reinforced plastic material is obtained, forming a solid piece with great structural rigidity.
  • the connection between the core 1 and the fiber-reinforced plastic material is a mechanical connection, as explained above, without the need for welds or gluing.
  • the plastic material that is injected in the second stage is welded due to the high temperature and pressure on the plastic material injected in the first stage, a solid piece of reinforced plastic of high quality being obtained and preventing the carrying out of additional visual checks.
  • a wind turbine blade 4 with lower manufacturing costs is obtained due to the lower cost of the materials used in the method described, these being the reinforced plastic or the steel plate, and to the reduced manufacturing-process times, both in a reinforced-plastic moulding process or in plate stamping.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Sustainable Energy (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Sustainable Development (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Composite Materials (AREA)
  • Wind Motors (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

Wind turbine blade that comprises a main body (5) that houses in its interior a core (1) to which is fixed said main body (5), wherein the core (1) comprises a center (2) made of metal or another material of similar characteristics, and the main body (5) is a piece of reinforced plastic moulded on said center (2).

Description

D E S C R I P T I O N "Wind turbine blade"
TECHNICAL FIELD
This invention relates to wind turbine blades and the method for their manufacture.
PRIOR ART There are in the prior art well known wind turbine blades and methods for their manufacture, wherein the blade has a core formed by one or more pieces, and the exterior is formed by a main body of reinforced plastic material in one or more pieces.
Patent application WO2010025830 discloses a wind turbine blade that comprises a main body formed by two or more connected sections, each one of which comprises at least one final area of thermoplastic material, said areas of adjacent sections being welded in their connection. The sections are shells formed by a polymer material, preferably epoxy resin, in their bodies and by thermoplastic material in their end zones, and are connected all the way along the blade. In their interior the sections have a core, which is a longitudinal reinforcement in the form of a quadrangular beam, formed by a fibre-reinforced epoxy resin and which is fixed to the main body. The method for connecting the adjacent sections comprises the connection of the thermoplastic end zones, their heating and fusion through different procedures, pressure in order to weld the connection and cooling.
DISCLOSURE OF THE INVENTION
It is an object of this invention to provide a wind turbine blade and a method for manufacturing wind turbine blades as described in the claims.
The wind turbine blade comprises a main body that houses in its interior a core to which is fixed said main body; the core comprises a center made of metal or another material of similar characteristics, and the main body is a piece of reinforced plastic moulded on said core.
A wind turbine blade is obtained by forming a solid piece with great structural rigidity. The connection between the core and the body is a mechanical connection that prevents welds or gluing.
These and other advantages and characteristics of the invention will be made evident in the light of the drawings and the detailed description thereof.
DESCRIPTION OF THE DRAWINGS
Figure 1 shows a view of the core of an embodiment of the wind turbine blade of the invention.
Figure 2 shows a view of the center of the core of Figure 1.
Figure 3 shows a view of the support of the core of Figure 1.
Figure 4 shows a view of an embodiment of the wind turbine blade of the invention.
Figure 5 shows a cross-section of the wind turbine blade with the center of the core of Figure 4.
Figure 6 shows another cross-section of the wind turbine blade with the center and the support of the core of Figure 4.
Figure 7 shows a cross-section of a semi-mould of an injection mould with the first semi-body of the main body in the cavity showing the mechanical connection between body and core.
Figure 8 shows an injection mould with two cavities.
Figure 9 shows an injection mould of one cavity showing the moving means.
DETAILED DISCLOSURE OF THE INVENTION
Figures 1 to 3 show the pieces that form the core 1 of the wind turbine blade 4 according to one embodiment. In said embodiment the core 1 is formed by the connection of a center 2 and a support 3. The center 2 is a piece made of metal or another material of similar characteristics, preferably a stamped steel plate, which has a warped section on one part of its length to form a piece in the form of a thin sheet, and disposed with a series of inserts and holes that reinforce the rigidity of the piece and enable the flow of the reinforced plastic between the faces of the center 2, increasing the pressure between the center 2 and the plastic, and making the mechanical connection of the pieces easier.
The support 3 is a piece made of metal or another material of similar characteristics, preferably a stamped steel plate that is connected at one end to the center 2 in different alternative forms, by welding, screwing or crimping. The other end of the support is connected to the wind turbine.
In another embodiment, the center 2 is a piece of fibre-reinforced plastic material, preferably thermostable or thermoplastic.
Figures 4 to 6 show the wind turbine blade 4 according to one embodiment.
In said embodiment the wind turbine blade 4 is formed by a core 1 and a main body 5. The main body 5 is a piece of fiber-reinforced plastic, preferably fiberglass- reinforced polypropylene. In another embodiment the plastic material of the main body 5 is thermostable or thermoplastic and fiber- reinforced, such as BMC.
The fiberglass is mixed inside the flow of the plastic material, and is distributed with it all along the extension of the main body 5 in different directions. In other embodiments the fibres that reinforce the plastic material that forms the main body 5 or the center 2 are natural fibres, carbon nanotubes or another type of nano reinforcement.
Due to the fact that the wind turbine blade 4 is a piece that will be exposed to the elements, additives must be added to the reinforced plastic material to improve its behaviour against ultra-violet rays and climate conditions.
The method for manufacturing the wind turbine blade 4, based on a preformed core 1 , is a moulding process. This moulding process is by injection or compression, the preferred embodiment being formed by an injection process, preferably by the injection of high-pressure long fibre, known as IMC.
Figure 7 shows a cross-section of a semi-mould 7 of an injection mould 8, with the first semi-body 11 of the main body 5 obtained with the method for manufacturing a wind turbine blade 4, formed by high-pressure injection. This method comprises two stages: in the first the pre-formed core 1 is placed in a cavity 6 of a semi-mould 7 of an injection mould 8, with the assistance of manual or automatic means. It is supported substantially on one of its faces to prevent it from deforming, and is held with means such as magnets, hooks or similar means. A series of holes 9 of the core 1 coincide with holes or recesses of the semi-mould 10 where the core 1 is supported. The plastic material reinforced with fibres, mixed with it beforehand, is injected on the face that is not supported and a first semi-body 1 1 of the main body 5 connected to the core 1 is obtained. In the injection the plastic material runs between the faces of the core 1 , flowing through the holes 9, and filling the holes or recesses of the top semi-mould 10, connecting the first semi-body 1 1 and the core 1 mechanically as it increases the pressure between them.
In the second stage fiber-reinforced plastic material is injected on the free face of the unit formed by the semi-body 1 1 and the core 1 , a second semi-body 12 of the main body 5 connected to the preceding unit being obtained, and a complete wind turbine blade 4 thereby being achieved. The connection between the semi-body 12 and the unit formed by the semi-body 11 and the core 1 occurs when the plastic material reinforced in this second stage is over-injected on the plastic material injected in the first stage, achieving the welding of both.
Figure 8 shows an injection mould 8 of two cavities, used to perform the high- pressure injection process in two stages, according to the method for manufacturing a wind turbine blade 4 in a preferred embodiment. The first stage of the method is performed in the first cavity 6, and the second stage in the second cavity 13, for which purpose the unit formed by the first semi-body 11 and the core 1 of the first cavity 6 is removed beforehand, with the assistance of manual or automatic means, and then turned round and placed in the cavity 13, with the complete wind turbine blade 4 being completed in one injection. For this purpose, in the first injection of the manufacturing process only a unit formed by the first semi-body 11 and the core 1 is obtained, although from the second injection and in each successive injection a core 1 is placed in the first cavity 6 and a semi-body 1 1 and core 1 unit in the second cavity 13. The injection mould 8 is closed and with one injection a semi-body 1 1 and core 1 unit is obtained from the first cavity 6 and a complete wind turbine blade 4 from the second cavity 13.
Figure 9 shows a one cavity injection mould 8, used to perform the high- pressure injection process in two stages, according to the method for manufacturing a wind turbine blade 4 in another embodiment. The two stages of the method are performed in the same cavity 6, and for this purpose in the first injection of the process the core 1 is supported substantially on one of its faces, to prevent it from deforming, on moving means 14 situated in the semi-mould 10. The fiber-reinforced plastic material is injected on the free face and a first semi-body 1 1 of the main body 5 connected to the core 1 is obtained. In the second stage the moving means 14 are removed and fiber-reinforced plastic material is injected on the free face of the unit formed by the semi-body 11 and the core 1 , a second semi-body 12 of the main body 5 connected to the preceding unit being obtained, and a complete wind turbine blade 4 thereby being created. In this embodiment a complete blade 4 is obtained in a double injection.
In both embodiments a cooling time inside the mould 8 is necessary so that the plastic material can cool, as it is injected at a high temperature. This cooling time is determined by the thickness of the piece, among other parameters.
The method for manufacturing the wind turbine blade 4 based on a core 1 has alternative final phases such as the deburring of the piece, required until the moulding process in refined, and the painting of the piece in accordance with customer requirements.
With this method a wind turbine blade that has a core 1 surrounded by a main body 5 of fiber-reinforced plastic material is obtained, forming a solid piece with great structural rigidity. The connection between the core 1 and the fiber-reinforced plastic material is a mechanical connection, as explained above, without the need for welds or gluing. In addition, the plastic material that is injected in the second stage is welded due to the high temperature and pressure on the plastic material injected in the first stage, a solid piece of reinforced plastic of high quality being obtained and preventing the carrying out of additional visual checks.
As a result, a wind turbine blade 4 with lower manufacturing costs is obtained due to the lower cost of the materials used in the method described, these being the reinforced plastic or the steel plate, and to the reduced manufacturing-process times, both in a reinforced-plastic moulding process or in plate stamping.

Claims

CLAIMS 1. Wind turbine blade that comprises a main body (5) that houses in its interior a core (1) to which is fixed said main body (5), characterised in that the core (1) comprises a center (2) made of metal or another material of similar characteristics, and the main body (5) is a piece of reinforced plastic moulded on said core (2).
2. Wind turbine blade according to claim 1 , wherein the main body (5) is injection-moulded, preferably at high pressure.
3. Wind turbine blade according to claims 1 or 2, wherein the center (2) is a piece in the form of a thin sheet that comprises a plurality of holes (9), said holes being filled by the main body (5).
4. Wind turbine blade according to claim 3, wherein the main body (5) is formed by a first semi-body (1 1) moulded on one of the faces of the center (2) and a second semi-body (12) moulded on the other face of said center (2).
5. Wind turbine blade according to any of claims 1 to 4, wherein the center (2) is a stamped steel plate.
6. Wnd turbine blade according to any of claims 1 to 4, wherein the center (2) is a piece of plastic material, preferably thermostable or thermoplastic, and fiber- reinforced.
7. Wnd turbine blade according to any of the preceding claims, wherein the core (1) comprises a support (3) made of metal or another material of similar characteristics connected to the center (2), the main body (5) being partially moulded on said support (3).
8. Wnd turbine blade according to claim 7, wherein the support (3) is connected to the center (2) by welding, screwing or crimping.
9. Wnd turbine blade according to any of the preceding claims, wherein the main body (5) is a piece of reinforced polypropylene.
10. Wind turbine blade according to any of the preceding claims, wherein the main body (5) is reinforced with fiberglass, natural fibres, carbon nanotubes, or nano reinforcements made of other materials.
1 1. Method for manufacturing a wind turbine blade (4) that comprises a main body (5) that houses in its interior a core (1) to which is fixed said main body (5), the core (1) comprising a center (2) made of metal or another material of similar characteristics, and the main body (5) being a piece of reinforced plastic, characterised in that it comprises
a first stage in which the pre-formed core (1) is positioned in a cavity (6) of a mould (8), is supported substantially on one of its faces and the reinforced plastic is moulded on the free face, a first semi-body (1 1) of the main body (5) being obtained, and
a second stage wherein the unit formed by the core (1) and the first semi- body (1 1) is housed in a cavity (6, 13) of a mould (8) and the reinforced plastic is moulded on the other face of the core (1), a second semi-body (12) of the main body (5) being obtained and said main body (5) thus being configured.
12. Method according to claim 11 , wherein the center (2) comprises a plurality of holes (9), and the plastic is made to flow through said holes (9) in the first stage.
13. Method according to claims 11 or 12, wherein the mould (8) has two cavities (6, 13), one cavity (6) being used for the first stage and the other cavity (13) for the second stage, with the result that the first semi-body (11) of a first blade (4) and the second semi-body of a second blade (4) are configured at the same time.
14. Method according to claims 11 or 12, wherein the mould (8) has one cavity (6), said cavity (6) being used for the two stages, the core (1) being placed on moving means (13) in the first stage and said moving means (13) being removed for the second stage.
15. Method according to any of claims 11 to 14, wherein the moulding process is performed by injection, preferably at high pressure.
PCT/EP2011/064907 2010-09-01 2011-08-30 Wind turbine blade WO2012028615A2 (en)

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US4648921A (en) * 1980-10-02 1987-03-10 United Technologies Corporation Method of making fiber reinforced articles
US20070251090A1 (en) * 2006-04-28 2007-11-01 General Electric Company Methods and apparatus for fabricating blades
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WO2010025830A2 (en) 2008-09-04 2010-03-11 Vestas Wind Systems A/S Wind turbine blade formed of connected sections

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2662204A1 (en) * 2012-05-07 2013-11-13 Nordex Energy GmbH Method, pre-fabricated construction element and mould for producing a wind energy facility component
US9541068B2 (en) 2012-05-07 2017-01-10 Nordex Energy Gmbh Method, prefabricated structural element and mold for making a wind turbine member
US10406781B2 (en) * 2016-04-28 2019-09-10 Hyundai Motor Company Composite material with insert-molded attachment steel

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ES2391016B1 (en) 2013-10-17
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