阅读说明：本技术 真空成型模具组件和相关联的方法 (Vacuum forming mold assembly and associated method ) 是由 J.R.托宾 B.阿亚萨米 A.麦卡利普 于 2018-11-05 设计创作，主要内容包括：本公开涉及一种用于产生真空成型模具组件的方法。方法包括形成多个支承板。各个支承板包括限定与模具腔的至少部分的横截面对应的形状的表面。方法还包括使模具主体可移除地联接到多个支承板以形成模具组件。模具主体在可移除地联接到多个支承板之后与各个支承板的表面的形状相符,使得模具主体限定模具组件的模具腔的至少部分。模具主体限定一个或多个真空歧管或一个或多个流体通路中的至少一个。(The present disclosure relates to a method for producing a vacuum forming mold assembly. The method includes forming a plurality of support plates. Each support plate includes a surface defining a shape corresponding to a cross-section of at least a portion of the mold cavity. The method also includes removably coupling the mold body to a plurality of support plates to form a mold assembly. The mold body conforms to a shape of a surface of each support plate after being removably coupled to the plurality of support plates such that the mold body defines at least a portion of a mold cavity of the mold assembly. The mold body defines at least one of one or more vacuum manifolds or one or more fluid passageways.)

1. A method for producing a vacuum forming mold assembly, the method comprising:

forming a plurality of support plates, each support plate including a surface defining a shape corresponding to a cross-section of at least a portion of a die cavity; and

removably coupling a mold body to the plurality of support plates to form the mold assembly, the mold body conforming to the shape of the surface of each support plate after being removably coupled to the plurality of support plates such that the mold body defines at least a portion of a mold cavity of the mold assembly, the mold body defining at least one of one or more vacuum manifolds or one or more fluid passageways.

2. The method of claim 1, further comprising:

deforming the die body such that the die body conforms to the shape of the surface of one or more support plates prior to removably coupling the die body to the plurality of support plates.

3. The method of claim 1, wherein a platform is formed on a top surface of the mold body, the platform configured to form one or more joint, connection, or alignment features.

4. The method of claim 1, further comprising:

positioning one or more base plates of the die body on the surface of each support plate;

deforming the one or more base plates such that the die body conforms to the shape of the surface of each support plate;

positioning one or more top plates of the mold body on the one or more base plates; and

deforming the one or more top plates such that the one or more top plates conform to the shape of the one or more base plates, the one or more top plates defining the mold cavity.

5. The method of claim 4, further comprising:

forming one or more grooves in a top surface of the mold body, the one or more grooves in fluid communication with the mold cavity, the grooves further configured to be fluidly coupled to a vacuum source via one or more vacuum ports.

6. The method of claim 4, further comprising:

positioning one or more tubes between one or more of the base plates of the mold body and one or more of the top plates of the mold body, one or more of the tubes defining one or more of the fluid passageways.

7. The method of claim 1, further comprising:

a plurality of vacuum passages are formed within the mold body that fluidly couple the mold cavity and the vacuum manifold.

8. The method of claim 1, further comprising:

positioning a gasket around a perimeter of a top surface of the mold body, the gasket configured to seal between the mold body and a sheet positioned on the mold body.

9. The method of claim 1, further comprising:

the plurality of support plates are positioned such that the individual support plates are spaced apart from each other in a spanwise direction.

10. The method of claim 1, wherein the mold body comprises a plurality of mold body segments, the method further comprising:

removably coupling each of the plurality of mold body sections together.

11. A vacuum forming die assembly comprising:

a plurality of support plates, each support plate including a surface defining a shape corresponding to a cross-section of at least a portion of a die cavity; and

a mold body removably coupled to the plurality of support plates, the mold body conforming to the shape of the surface of each support plate after being removably coupled to the plurality of support plates such that the mold body defines at least a portion of a mold cavity of the mold assembly, the mold body defining at least one of one or more vacuum manifolds or one or more fluid passageways.

12. The vacuum forming die assembly of claim 11, wherein the die body is planar prior to being removably coupled to the plurality of support plates, the die body configured to deform when removably coupled to the plurality of support plates such that the die body conforms to the shape of the surface of each support plate.

13. The vacuum forming die assembly of claim 11, wherein a platform is located on a top surface of the die body, the platform configured to form one or more joint features, connection features, or alignment features.

14. The vacuum forming die assembly of claim 11, wherein the die plates include one or more base plates positioned on the surface of each support plate that conform to the shape of each support plate and one or more top plates positioned on the one or more base plates that conform to the shape of the one or more base plates that define the die cavity.

15. The vacuum forming die assembly of claim 14, wherein a top surface of the one or more top plates defines one or more grooves in fluid communication with the die cavity, the grooves further configured to be fluidly coupled to a vacuum source via one or more vacuum ports.

16. The vacuum forming die assembly of claim 14, wherein the die body further comprises one or more tubes positioned between the one or more base plates and the one or more top plates, the one or more tubes defining one or more of the one or more fluid passageways.

17. The vacuum forming die assembly of claim 11, wherein the die body defines a plurality of vacuum passages fluidly coupling the die cavity and the vacuum manifold.

18. The vacuum forming die assembly of claim 11, further comprising:

a gasket around a perimeter of a top surface of the mold body, the gasket configured to seal between the mold body and a sheet positioned on the mold body.

19. The vacuum forming die assembly of claim 11, wherein the support plates are spaced apart from each other in a spanwise direction.

20. The vacuum forming die assembly of claim 11, wherein the die body comprises a plurality of die body segments removably coupled together.

Technical Field

The present disclosure generally relates to vacuum forming molds. More particularly, the present disclosure relates to vacuum forming die assemblies such as for use in forming wind turbine components and associated methods for producing vacuum forming die assemblies.

Background

Wind power is considered one of the cleanest, most environmentally friendly energy sources presently available, and wind turbines have gained increased attention in this regard. Modern wind turbines typically include a tower, a nacelle mounted on the tower, a generator positioned in the nacelle, and one or more rotor blades. One or more rotor blades use known airfoil principles to convert kinetic energy of wind into mechanical energy. The drive train transfers mechanical energy from the rotor blades to the generator. The generator then converts the mechanical energy to electrical energy that may be supplied to a utility grid.

Each rotor blade generally includes various shell portions, such as a pressure side shell and a suction side shell that are joined together along leading and trailing edges of the rotor blade. The shell is formed using a suitable mold. For example, in some cases, the mold may be formed via sand casting. After casting, the mold may be finished to improve its dimensional accuracy and/or surface finish. However, such finishing operations are time consuming and expensive in view of the large size of many wind turbine rotor blades, thereby increasing the overall cost of the wind turbine. Furthermore, such a mould is difficult to modify when the design of the rotor blade is changed. As such, when modifications to the rotor blade design are made, new molds are required.

Accordingly, improved vacuum forming mold assemblies and methods for producing vacuum forming mold assemblies would be welcomed in the art.

Disclosure of Invention

Aspects and advantages of the present technology will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the present technology.

In one aspect, the present disclosure is directed to a method for producing a vacuum forming mold assembly. The method includes forming a plurality of support plates. Each support plate includes a surface defining a shape corresponding to a cross-section of at least a portion of the mold cavity. The method also includes removably coupling the mold body to a plurality of support plates to form a mold assembly. The mold body conforms to a shape of a surface of each support plate after being removably coupled to the plurality of support plates such that the mold body defines at least a portion of a mold cavity of the mold assembly. The mold body defines at least one of one or more vacuum manifolds or one or more fluid passageways.

In another aspect, the present disclosure is directed to a vacuum forming mold assembly. The vacuum forming die assembly includes a plurality of support plates. Each support plate includes a surface defining a shape corresponding to a cross-section of at least a portion of the mold cavity. The vacuum forming die assembly also includes a die body removably coupled to the plurality of support plates. The mold body conforms to a shape of a surface of each support plate after being removably coupled to the plurality of support plates such that the mold body defines at least a portion of a mold cavity of the mold assembly. The mold body defines at least one of one or more vacuum manifolds or one or more fluid passageways.

These and other features, aspects, and advantages of the present technology will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the technology and together with the description, serve to explain the principles of the technology.

Drawings

A full and enabling disclosure of the present technology, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 is a perspective view of one embodiment of a wind turbine according to aspects of the present disclosure;

FIG. 2 is a perspective view of an embodiment of a modular rotor blade of a wind turbine according to aspects of the present disclosure;

FIG. 3 is an exploded view of the modular rotor blade shown in FIG. 2, in accordance with aspects of the present disclosure;

FIG. 4 is a cross-sectional view of an embodiment of a leading edge segment of a modular rotor blade according to aspects of the present disclosure;

FIG. 5 is a cross-sectional view of an embodiment of a trailing edge segment of a modular rotor blade according to aspects of the present disclosure;

FIG. 6 is a cross-sectional view of the modular rotor blade of FIG. 2, according to aspects of the present disclosure;

FIG. 7 is a cross-sectional view of the modular rotor blade of FIG. 2, according to aspects of the present disclosure;

FIG. 8 is a perspective view of one embodiment of a vacuum forming mold assembly according to aspects of the present disclosure;

FIG. 9 is a perspective view of one embodiment of a vacuum forming die assembly illustrating a plurality of spaced apart support plates of the vacuum forming die assembly, in accordance with aspects of the present disclosure;

FIG. 10 is a perspective view of one embodiment of a mold body section of a vacuum forming mold assembly according to aspects of the present disclosure;

FIG. 11 is an elevation view of an embodiment of a pair of mold body sections coupled together according to aspects of the present disclosure;

FIG. 12 is an elevation view of an embodiment of a portion of a vacuum forming die assembly illustrating pairs of die body segments removably coupled to a support plate according to aspects of the present disclosure;

FIG. 13 is a perspective view of a portion of a vacuum forming die assembly, particularly illustrating a plurality of brackets removably coupling pairs of die body segments to a support plate, in accordance with aspects of the present disclosure;

FIG. 14 is a perspective view of another embodiment of a vacuum forming mold assembly according to aspects of the present disclosure;

FIG. 15 is an exploded perspective view of the vacuum forming mold assembly shown in FIG. 14, in accordance with aspects of the present disclosure;

FIG. 16 is a side view of one embodiment of a support plate of a vacuum forming die assembly according to aspects of the present disclosure;

FIG. 17 is a perspective view of a portion of one embodiment of a mold body of a vacuum forming mold assembly, according to aspects of the present disclosure;

FIG. 18 is a partially exploded perspective view of the vacuum forming die shown in FIGS. 14 and 15, illustrating the die body prior to being removably coupled to the plurality of support plates;

FIG. 19 is a perspective view of a portion of a vacuum forming die assembly illustrating a die body removably coupled to a plurality of support plates according to aspects of the present disclosure;

FIG. 20 is a perspective view of the embodiment of the vacuum forming mold assembly shown in FIG. 14 illustrating an exploded view of the platform of the mold assembly;

FIG. 21 is a perspective view of the embodiment of the vacuum forming mold assembly shown in FIGS. 14 and 20 illustrating a gasket of the mold assembly; and

fig. 22 is a flow chart illustrating one embodiment of a method for creating a vacuum forming mold assembly in accordance with aspects of the present disclosure.

Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the present technology.

Detailed Description

Reference will now be made in detail to the present embodiments of the technology, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. The same or similar reference numbers have been used in the drawings and the description to refer to the same or similar parts of the technology. As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another, and are not intended to indicate the location or importance of the individual components.

Various examples are provided by way of explanation of the present technology, not limitation of the present technology. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present technology without departing from the scope or spirit of the technology. For instance, features illustrated or described as part of one embodiment, can be used on another embodiment to yield a still further embodiment. It is therefore intended that the present technology cover such modifications and variations as come within the scope of the appended claims and their equivalents.

Referring now to the drawings, FIG. 1 illustrates a perspective view of one embodiment of an exemplary wind turbine 10 according to the present disclosure. As shown, wind turbine 10 generally includes: a tower 12 extending from a support surface 14; a nacelle 16 mounted on the tower 12; and a rotor 18 coupled to nacelle 16. The rotor 18 includes: a rotatable hub 20; and at least one rotor blade 22 coupled to hub 20 and extending outwardly from hub 20. For example, in the embodiment illustrated in FIG. 1, rotor 18 includes three rotor blades 22. However, in alternative embodiments, rotor 18 may include more or less than three rotor blades 22. Each rotor blade 22 may be spaced about hub 20 to facilitate rotating rotor 18 to enable kinetic energy to be transferred from the wind into usable mechanical energy, and subsequently, electrical energy. For example, hub 20 may be rotatably coupled to a generator 24 positioned within nacelle 16.

Referring now to FIGS. 2 and 3, various views of a rotor blade 16 according to the present disclosure are illustrated. As shown, the illustrated rotor blade 22 has a segmented or modular configuration. It should also be appreciated that rotor blade 22 may include any other suitable configuration now known or later developed in the art. As shown, the modular rotor blade 22 includes a primary blade structure 26 constructed at least partially of a thermoset material and/or a thermoplastic material and at least one blade segment 28 configured with the primary blade structure 26. More specifically, as shown, the rotor blade 22 includes a plurality of blade segments 28. The blade segment(s) 28 may also be at least partially constructed of a thermoset material and/or a thermoplastic material.

Thermoplastic rotor blade components and/or materials as described herein generally comprise plastic materials or polymers that are reversible in nature. For example, thermoplastic materials typically become pliable or moldable when heated to a certain temperature and return to a more rigid state when cooled. Further, the thermoplastic material may include an amorphous thermoplastic material and/or a semi-crystalline thermoplastic material. For example, some amorphous thermoplastic materials may generally include, but are not limited to, styrene, vinyl, cellulosics, polyesters, acrylics, polysulfones, and/or imides. More specifically, exemplary amorphous thermoplastic materials may include polystyrene, Acrylonitrile Butadiene Styrene (ABS), polymethyl methacrylate (PMMA), ethylene glycol terephthalate (PET-G), polycarbonate, polyvinyl acetate, amorphous polyamide, polyvinyl chloride (PVC), polyvinylidene chloride, polyurethane, or any other suitable amorphous thermoplastic material. Additionally, exemplary semi-crystalline thermoplastic materials may generally include, but are not limited to, polyolefins, polyamides, fluoropolymers, ethyl methacrylate, polyesters, polycarbonates, and/or acetals. More specifically, exemplary semi-crystalline thermoplastic materials may include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polypropylene, polyphenylene sulfide, polyethylene, polyamide (nylon), polyether ketone, or any other suitable semi-crystalline thermoplastic material.

Further, thermoset components and/or materials as described herein generally comprise plastic materials or polymers that are irreversible in nature. For example, thermoset materials, once cured, cannot be easily remolded or returned to a liquid state. As such, after initial molding, thermosets are generally resistant to heat, corrosion, and/or creep. Example thermoset materials may generally include, but are not limited to, some polyesters, some polyurethanes, esters, epoxies, or any other suitable thermoset material.

Additionally, as mentioned, thermoplastic materials and/or thermoset materials as described herein may optionally be reinforced with fibrous materials including, but not limited to, glass fibers, carbon fibers, polymer fibers, wood fibers, bamboo fibers, ceramic fibers, nanofibers, metal fibers, or the like, or combinations thereof. Additionally, the direction of the fibers may include a multi-axial direction, a unidirectional direction, a biaxial direction, a tri-axial direction, or any other suitable direction and/or combinations thereof. Further, the fiber content may vary depending on the stiffness required in the corresponding blade component, the area or location of the blade component in the rotor blade 22, and/or the desired weldability of the component.

More specifically, as shown, the primary blade structure 26 may include any one or combination of the following: the pre-formed blade root section 30, the pre-formed blade tip section 32, one or more continuous spar caps 34, 36, 38, 40, one or more shear webs 42 (FIGS. 6-7), additional structural components 44 secured to the blade root section 30, and/or any other suitable structural components of the rotor blade 22. Moreover, blade root section 30 is configured to be mounted or otherwise secured to hub 20 (FIG. 1). Further, as shown in FIG. 2, the rotor blade 22 defines a span 46, the span 46 being equal to the total length between the blade root section 30 and the blade tip section 32. As shown in FIGS. 2 and 6, the rotor blade 22 also defines a chord 48, the chord 48 being equal to the total length between a leading edge 50 of the rotor blade 22 and a trailing edge 52 of the rotor blade 22. As generally understood, the chord 48 may generally vary in length with respect to the span 46 as the rotor blade 22 extends from the blade root section 30 to the blade tip section 32.

2-4, any number of blade segments 28 or panels having any suitable size and/or shape may be arranged generally in a generally spanwise direction along the longitudinal axis 54 between the blade root section 30 and the blade tip section 32. As such, the blade segment 28 generally functions as a shell/cover for the rotor blade 22 and may define a substantially aerodynamic profile, such as by defining a symmetrical or curved airfoil-shaped cross-section. In additional embodiments, it should be understood that the blade segment portions of the blade 22 may include any combination of the segments described herein and are not limited to the embodiments as depicted. Additionally, blade segments 28 may be constructed from any suitable material including, but not limited to, thermoset or thermoplastic materials that are optionally reinforced with one or more fiber materials. More specifically, in certain embodiments, blade panel 28 may include any one or combination of the following: pressure side segments 56 and/or suction side segments 58 (fig. 2 and 3), leading edge segments 60 and/or trailing edge segments 62 (fig. 2-6), jointless segments, single joint segments, multi-joint blade segments, J-shaped blade segments, or the like.

More specifically, as shown in FIG. 4, the leading edge segment 60 may have a forward pressure side surface 64 and a forward suction side surface 66. Similarly, as shown in FIG. 5, each of the trailing edge segments 62 may have an aft pressure side surface 68 and an aft suction side surface 70. Thus, the forward pressure side surface 64 of the leading edge segment 60 and the aft pressure side surface 68 of the trailing edge segment 62 generally define the pressure side surface of the rotor blade 22. Similarly, the forward suction side surface 66 of the leading edge segment 60 and the aft suction side surface 70 of the trailing edge segment 62 generally define a suction side surface of the rotor blade 22. Additionally, as particularly shown in FIG. 6, leading edge segment(s) 60 and trailing edge segment(s) 62 may be joined at a pressure side seam 72 and a suction side seam 74. For example, the blade segments 60, 62 may be configured to overlap at the pressure side seam 72 and/or the suction side seam 74. Further, as shown in FIG. 2, adjacent blade segments 28 may be configured to overlap at a seam 76. Thus, where the blade segments 28 are at least partially constructed of a thermoplastic material, adjacent blade segments 28 may be welded together along seams 72, 74, 76, which will be discussed in greater detail herein. Alternatively, in certain embodiments, the various segments of the rotor blade 22 may be secured together via adhesives (or mechanical fasteners) configured between overlapping leading and trailing edge segments 60, 62 and/or overlapping adjacent leading or trailing edge segments 60, 62.

In particular embodiments, as shown in fig. 2-3 and 6-7, blade root section 30 may include one or more longitudinally extending spar caps 34, 36 that are infused therewith. For example, the Blade Root Section 30 may be constructed according to U.S. application No. 14/753155, filed on 29.6.2015, entitled "Blade Root Section for a modular rotor Blade and Method of Manufacturing Same", which is incorporated herein by reference in its entirety.

Similarly, the blade tip section 32 may include one or more longitudinally extending spar caps 38, 40 that are infused therewith. More specifically, as shown, the spar caps 34, 36, 38, 40 may be configured to engage against opposing inner surfaces of the blade segments 28 of the rotor blade 22. Further, the blade root spar caps 34, 36 may be configured to align with the blade tip spar caps 38, 40. As such, the spar caps 34, 36, 38, 40 may generally be designed to control bending stresses and/or other loads acting on the rotor blade 22 in a generally spanwise direction (a direction parallel to the span 46 of the rotor blade 22) during operation of the wind turbine 10. Additionally, the spar caps 34, 36, 38, 40 may be designed to withstand spanwise compression that occurs during operation of the wind turbine 10. Further, the spar cap(s) 34, 36, 38, 40 may be configured to extend from the blade root section 30 to the blade tip section 32, or portions thereof. Thus, in certain embodiments, the blade root section 30 and the blade tip section 32 may be joined together via their respective spar caps 34, 36, 38, 40.

Additionally, the spar caps 34, 36, 38, 40 may be constructed from any suitable material (e.g., a thermoplastic material or a thermoset material, or a combination thereof). Further, spar caps 34, 36, 38, 40 may be pultruded from a thermoplastic resin or a thermoset resin. As used herein, the terms "pultrusion," "pultrusion," or similar terms generally encompass reinforcing materials (e.g., fibers or woven or braided strands) that are impregnated with a resin and pulled through a stent such that the resin cures or undergoes polymerization. As such, the process of making pultruded components is typically characterized as a continuous process that produces a composite material having a composite part with a constant cross-section. Thus, the pre-cured composite material may comprise a pultrusion composed of a reinforced thermoset or thermoplastic material. Further, the spar caps 34, 36, 38, 40 may be formed from the same pre-cured composite or different pre-cured composites. In addition, the pultruded elements may be produced from rovings, which generally contain long and narrow fiber bundles that are not combined until joined by a cured resin.

Referring to fig. 6-7, one or more shear webs 42 may be configured between one or more spar caps 34, 36, 38, 40. More specifically, the shear web(s) 42 may be configured to increase rigidity in the blade root section 30 and/or the blade tip section 32. Further, the shear web(s) 42 may be configured to enclose the blade root section 30.

Additionally, as shown in FIGS. 2 and 3, additional structural members 44 may be secured to the blade root section 30 and extend in a generally spanwise direction to provide further support to the rotor blade 22. For example, the Structural member 44 may be constructed in accordance with U.S. application Ser. No. 14/753150 filed on 29.6.2015 entitled "Structural Component for a Modular rotor Blade", which is incorporated herein by reference in its entirety. More specifically, structural members 44 may extend any suitable distance between blade root section 30 and blade tip section 32. As such, the structural members 44 are configured to provide additional structural support for the rotor blade 22 as well as optional mounting structure for the various blade segments 28 as described herein. For example, in certain embodiments, the structural member 44 may be fixed to the blade root section 30 and may extend a predetermined spanwise distance such that the leading edge segment 60 and/or the trailing edge segment 62 may be mounted to the structural member 44.

Fig. 8-13 illustrate one embodiment of a mold assembly 100 according to aspects of the present disclosure. In general, the mold assembly 100 is configured for vacuum forming a variety of thermoplastic components. For example, the mold assembly 100 may be configured to form one of the blade segments 28 of the rotor blade 22, such as one of the pressure side segment 56, the suction side segment 58, the leading edge segment 60, and/or the trailing edge segment 62. However, in alternative embodiments, mold assembly 100 may be configured to form any other suitable thermoplastic component for use in any other suitable application (including applications other than wind turbines). Further, in one embodiment, the mold assembly 100 may be configured for placement within a bed (bed) of an additive manufacturing device, such as a three-dimensional printer (not shown).

As illustrated in fig. 8-13, the mold assembly 100 defines a plurality of orientations. More specifically, in several embodiments, the orientation of the mold assembly 100 may be defined relative to the particular component (e.g., blade segment 28) that the mold assembly 100 is configured to form. As such, in the illustrated embodiment, the mold assembly 100 defines a spanwise direction (e.g., as indicated by arrow 102 in fig. 8-13) extending between a root side 104 of the mold assembly 100 and a tip side 106 of the mold assembly 100. Mold assembly 100 also defines a chordwise direction (e.g., as indicated by arrow 108 in fig. 8-13) extending between leading edge side 110 of mold assembly 100 and trailing edge side 112 of mold assembly 100. Further, the mold assembly 100 defines a vertical direction (e.g., as indicated by arrow 114 in fig. 8-11) extending between a bottom side 116 of the mold assembly 100 and a top side 118 of the mold assembly 100. However, in alternative embodiments, the mold assembly 100 may define other directions in addition to or instead of the spanwise direction 102, the chordwise direction 108, and the vertical direction 114, depending on the particular configuration of the thermoplastic members.

As shown in fig. 8 and 9, the die assembly 100 includes a plurality of spaced apart support plates 120. In general, the support plate 120 is configured to support a mold body 122 of the mold assembly 100 relative to a base frame 124 (fig. 14) of the mold assembly 100. In this regard, each support plate 120 may have a beam-like configuration. Furthermore, as will be described in greater detail below, each support plate 120 includes a top surface 126, the top surface 126 defining a shape corresponding to a cross-section of at least a portion of a die cavity 128 of the die assembly 100. Additionally, in the illustrated embodiment, the support plates 120 may be spaced apart along the spanwise direction 102. However, in alternative embodiments, support plates 120 may be spaced apart along chordwise direction 108 or any other suitable direction. Additionally, although the die assembly 100 is shown with a particular number of back plates 120, the die assembly 100 may include any suitable number of back plates 120.

Mold assembly 100 also includes a plurality of mold body segments 130. As will be described in greater detail below, the mold body segments 130 are removably coupled together to form the mold body 122 of the mold assembly 100. In the embodiment illustrated in fig. 8, mold assembly 100 includes a particular number of mold body segments 130. However, in alternative embodiments, mold assembly 100 may include any suitable number of mold body sections 130. Further, in several embodiments, the mold body segments 130 may be formed from aluminum and any other suitable material.

Fig. 10 illustrates one of the mold body segments 130 in more detail. As shown, each mold body segment 130 includes: a top surface 132 at least partially defining the mold cavity 128; and a bottom surface 134 vertically spaced from the top surface 132. In this regard, the first surface 132 of the mold body section 130 may be positioned at or near the top side 118 of the mold assembly 100, while the bottom surface 134 of the mold body section 130 may be positioned at or near the bottom side 114 of the mold assembly 100. As such, the mold body segment 130 defines a thickness (e.g., as indicated by arrow 136 in fig. 10) that extends vertically between the top surface 132 and the bottom surface 134. In general, thickness 136 should be sized such that mold body segment 130 is able to bend or otherwise deform (e.g., elastically or plastically) to conform to top surface 126 of support plate 120. In one embodiment, each mold body segment 130 may be formed via extrusion. However, in alternative embodiments, each mold body segment 130 may be formed via any other suitable manufacturing process.

As shown, one or more of the mold body segments 130 may define one or more fluid passageways 138 extending therethrough. Generally, a heating fluid may flow through the fluid passages 138 in the mold body segments 130 to heat the mold body 122 for vacuum forming the thermoplastic sheet. However, in certain embodiments, a coolant may flow through the fluid passage 138 to cool the mold body 122. In one embodiment, the fluid passages 138 may extend through the mold body segments 130 in the spanwise direction 102. As such, the fluid passages 138 may be spaced apart from one another along the chordwise direction 108. However, in alternative embodiments, fluid passageways 138 may extend through mold body segments 130 in any suitable manner. Additional embodiments of mold body segments 130 may define more or fewer fluid passageways 138, including no fluid passageways 138 at all. In certain embodiments, an external heater (not shown) is coupled to the bottom surface 134 of one or more of the mold body segments 130. Such heating elements may heat the mold body 122 in addition to or in lieu of fluid flowing through the fluid passageway 138. For example, such heating elements may allow for selective heating of particular portions of the mold body 122.

One or more of the mold body segments 130 may also define one or more vacuum manifolds 140 extending therethrough. In one embodiment, the vacuum manifold 140 may extend through the mold body segments 130 in the spanwise direction 102. As such, the vacuum manifolds 140 may be spaced apart from each other along the chordwise direction 108. However, in alternative embodiments, the vacuum manifold 140 may extend through the mold body segments 130 in any suitable manner. In addition, one or more of the mold body segments 130 define a plurality of vacuum passages 142. As shown, each vacuum passage 142 fluidly couples a mold cavity 128 and a corresponding vacuum manifold 140. In this regard, each vacuum passageway 142 extends from the corresponding vacuum manifold 140 to the top surface 132 in a direction orthogonal to the top surface 132 of the mold body section 130. In operation, a vacuum may be applied to each vacuum manifold 140 by a suitable vacuum pump or another suitable vacuum source (not shown). As such, the vacuum conforms the thermoplastic sheet to the shape of mold cavity 128 (i.e., to top surface 132 of mold body segment 130).

In addition, the mold body segments 130 can also define a plurality of slots 144 extending therethrough. Generally, each slot 144 is configured to receive one or more fasteners 146, the fasteners 146 for coupling the associated die body segment 130 to the support plate 120. As shown, the slots 144 may extend vertically upward from the bottom surface 134 of the mold body section 130 toward the top surface 132 of the mold body section 130. In one embodiment, the slots 144 may extend through the mold body segments 130 in the spanwise direction 102. As such, the slots 144 may be spaced apart from one another along the chordwise direction 108. However, in alternative embodiments, slots 144 may extend through mold body segments 130 in any suitable manner. Further, in the illustrated embodiment, the fastener 146 may correspond to a T-bolt and associated nut. However, the fasteners 146 may correspond to any other suitable type of fastener.

Referring now to fig. 11, as mentioned above, the mold body segments 130 may be removably coupled together to form the mold body 122. For example, in one embodiment, the mold body segments 130 may be stacked together along the chordwise direction 108 and removably coupled together. However, in alternative embodiments, the mold body segments 130 may also be stacked together along the spanwise direction 102 and removably coupled together. To facilitate removable coupling, each mold body segment 130 can include: a first connection feature 148 positioned at one end of the mold body section 130; and second connection features 150 positioned at opposite ends of the mold body segments 130. Generally, the first connection feature 148 on one of the mold body sections 130 is configured to mate with or otherwise engage a second connection feature 150 of an adjacent mold body section 130. In the illustrated embodiment, the first and second connection features 148, 150 are complementary protrusions. A suitable fastener 152 (fig. 12) may couple the mating first and second connection features 148, 150.

Fig. 12 and 13 illustrate the die assembly 100 when the die body 122 is removably coupled to the support plate 120. Each mold body segment 130 rests on top surface 126 of support plate 120. In one embodiment, the mold body segments 130 may extend perpendicular to the support plate 120. For example, the mold body segments 130 may extend in the spanwise direction 102, while the support plates 120 may extend in the chordwise direction 108. However, in alternative embodiments, the mold body segments 130 may be arranged in any other suitable manner relative to the support plate 120. Each mold body segment 130 may then be coupled to one or more brackets 154 via fasteners 146. The bracket 154 may in turn be coupled to the support plate 120 by suitable fasteners 156. The mold body segments 130 may be removably coupled to one another to form the mold body 122 either before or after being removably coupled to the support plate 120. In addition, one or more vacuum hoses 158 may fluidly couple a vacuum source (not shown) to the vacuum manifold 140 defined by the mold body 122. Additionally, one or more fluid hoses 160 may fluidly couple a fluid source (not shown) to the fluid passageway 138 defined by the mold body 122.

After being coupled to the back plate 120, the die body 122 defines a die cavity 128. More specifically, as mentioned above, the top surface 126 of the back plate 120 defines a shape corresponding to the cross-section of a portion of the die cavity 128. For example, the top surface 126 of the back plate 120 may have the same or similar shape as the cross-sectional shape of the die cavity 128. As such, coupling the die body segment 130 to the support plate 120 conforms the die body segment 130 to the shape of the top surface 126 of the support plate 120. In several embodiments, as shown in fig. 10 and 11, prior to coupling to the support plate 120, the die body segments 130 are planar or otherwise flat. As such, coupling the die body segment 130 to the support plate 120 may deform or otherwise bend the die body segment 130 to conform to the shape of the top surface 126 of the support plate 120. After such deformation, a top surface 132 of the mold body segment 130 (which defines the same shape or a similar shape as the top surface 126 of the support plate 120) defines the mold cavity 128.

The mold assembly 100 may also include additional features. For example, the mold assembly 100 may include a gasket 264 (fig. 21) positioned around a perimeter thereof. Generally, the gasket 264 is configured to provide a seal between the mold body 122 and a thermoplastic sheet placed on the mold to be formed into a component. In certain embodiments, the gasket 264 is used when forming a component from reinforced thermoplastic sheets (e.g., fiberglass). For example, in one embodiment, the gasket 264 may be formed of silicone. In addition, the mold assembly 100 may include a platform 266 (fig. 20). As will be discussed in greater detail below, the platform 266 is raised relative to the top surface of the mold body 122. In this regard, the platform 266 may be configured to form one or more joint features. For example, the joint feature may be a portion of a lap joint on the formed component. The platform 266 may also be configured to form one or more connection features (such as dimples, cavities, recessed markings, and/or the like) in the blade segment 22, which may facilitate coupling blade attachment features (e.g., flow anchors, vortex generators, etc.) to the blade segment 22. Further, the platform 266 may be configured to form one or more alignment features (e.g., walls, ledges, bumps, protrusions, lines, ridges, pins, and/or the like) against which the thermoplastic sheet may abut.

Additionally, as shown in fig. 8, the mold body 122 may define one or more grooves 162 in its top surface 132. More specifically, groove 162 is in fluid communication with mold cavity 128. In addition, the groove 162 is also in fluid communication with a vacuum source (not shown) via one or more vacuum ports 164 defined by the mold body 122. In this regard, the groove 162 is configured to provide a vacuum to the mold cavity 128 that causes the thermoplastic sheet to adhere to the top surface 132 of the mold body 122. In the illustrated embodiment, the grooves 162 have a grid-like configuration. However, in alternative embodiments, the groove 162 may have any other suitable configuration and/or be present on any portion of the mold body 122. Further, the vacuum ports 164 are illustrated as being positioned proximate to an edge of the mold body 122. However, the vacuum port 164 may be positioned in any other suitable location of the mold body 122.

Fig. 14-19 illustrate another embodiment of a mold assembly 200 according to aspects of the present disclosure. Generally, the mold assembly 200 is configured for vacuum forming a variety of thermoplastic components. For example, the mold assembly 200 may be configured to form one of the blade segments 28 of the rotor blade 22, such as one of the pressure side segment 56, the suction side segment 58, the leading edge segment 60, and/or the trailing edge segment 62. However, in alternative embodiments, mold assembly 200 may be configured to form any other suitable thermoplastic component for use in any other suitable application (including applications other than wind turbines). Further, as will be described below, in one embodiment, the mold assembly 200 may be configured for placement within a base of an additive manufacturing device (e.g., a three-dimensional printer).

As illustrated in fig. 14-19, the mold assembly 200 defines a plurality of orientations. More specifically, in several embodiments, the orientation of the mold assembly 200 may be defined relative to the particular component (e.g., blade segment 28) that the mold assembly 200 is configured to form. As such, in the illustrated embodiment, the mold assembly 200 defines a spanwise direction (e.g., as indicated by arrow 202 in fig. 14-19) extending between a root side 204 of the mold assembly 200 and a tip side 206 of the mold assembly 200. Mold assembly 200 also defines a chordwise direction (e.g., as indicated by arrow 208 in fig. 14-19) extending between a leading edge side 210 of mold assembly 200 and a trailing edge side 212 of mold assembly 200. Further, the mold assembly 200 defines a vertical direction (e.g., as indicated by arrow 214 in fig. 14-19) extending between a bottom side 216 of the mold assembly 200 and a top side 218 of the mold assembly 200. However, in alternative embodiments, the mold assembly 200 may define other directions in addition to or instead of the spanwise direction 202, the chordwise direction 208, and the vertical direction 214, depending on the particular configuration of the thermoplastic member.

As shown in fig. 14 and 15, the die assembly 200 includes a plurality of spaced apart support plates 220. In general, the support plate 220 is configured to support a mold body 222 of the mold assembly 200 relative to a base frame (e.g., the base frame 124 shown in fig. 8 and 9) of the mold assembly 200. In this regard, each support plate 220 may have a beam-like configuration. In one embodiment, the support plates 220 may be removably coupled together by an end cap 224 to maintain a desired spacing between each of the support plates 220. In the illustrated embodiment, the support plates 220 may be spaced apart along the spanwise direction 202. However, in alternative embodiments, the support plates 220 may be spaced apart along the chordwise direction 208 or any other suitable direction. Additionally, although the die assembly 200 is shown with a particular number of support plates 220, the die assembly 200 may include any suitable number of support plates 220.

Fig. 16 illustrates one of the support plates 220 in more detail. As shown, the support plate 220 includes a top surface 226 and a bottom surface 228 vertically spaced from the top surface 226. In this regard, the top surface 226 of the support plate 220 may be positioned at or near the top side 218 of the mold assembly 200, while the bottom surface 228 of the support plate 220 may be positioned at or near the bottom side 216 of the mold assembly 200. Similarly, the support plate 220 includes a leading edge side surface 230 and a trailing edge surface 232 that is vertically spaced from the leading edge side surface 230. In this regard, the leading side surface 230 of the support plate 220 may be positioned at or near the leading side 210 of the mold assembly 200, while the trailing side surface 232 of the support plate 220 may be positioned at or near the trailing side 212 of the mold assembly 200. As will be described in greater detail below, the top surface 226 defines a shape corresponding to a cross-section of at least a portion of a mold cavity 234 (fig. 14) of the mold assembly 200. Further, the support plate 220 may define one or more grooves 236, the grooves 236 extending vertically downward from the top surface 226 toward the bottom surface 228. However, in alternative embodiments, the support plate 220 may have any other suitable configuration.

As indicated above, the mold assembly 200 includes a mold body 222. As illustrated in fig. 15 and 17, the mold body 222 may include one or more base plates 238 and one or more top plates 240. More specifically, each substrate 238 includes a top surface 242 and a bottom surface 244 vertically spaced from the top surface 242. Similarly, each top plate 240 includes a top surface 246 and a bottom surface 248 vertically spaced from the top surface 246. In several embodiments, the top surface 242 of the one or more base plates 238 is in contact with the bottom surface 248 of the one or more top plates 240 when the mold body 222 is assembled. In one embodiment, the base plate 238 may be corrugated or otherwise formed such that the mold body 222 defines one or more passageways 250 positioned vertically between the base plate 238 and the top plate 240. For example, the passages 250 may extend in the spanwise direction 202 and be spaced apart from one another in the chordwise direction 208. However, in alternative embodiments, the passages 250 may extend in any other suitable direction and/or be spaced apart from each other in any other suitable direction. Further, some embodiments of the mold body 222 may not include the passageway 250. Additionally, in further embodiments, the mold body 222 may include only one ply or more than two plies.

In embodiments where the mold body 22 defines the passageway 250, the mold body 222 may include one or more tubes 252. As shown, each tube 252 is positioned within one of the passageways 250. In this regard, the tube 252 is positioned vertically between the base plate 238 and the top plate 240. In addition, each tube 252 defines a fluid passage 254 extending therethrough. Generally, a heating fluid may flow through the fluid passages 254 in the tube 252 to heat the mold body 222 for vacuum forming the thermoplastic sheet. However, in certain embodiments, a coolant may flow through the fluid channels 254 to cool the mold body 222. In certain embodiments, in addition to or in lieu of fluid flowing through the fluid passages 254, an external heater (not shown) coupled to the bottom surface 244 of the base plate 238 of the mold body 222 may heat the mold body 222. For example, such heating elements may allow for selective heating of particular portions of the mold body 122.

Referring now to fig. 14, 18, and 19, the die body 222 is removably coupled to the support plate 220. More specifically, the mold body 222 may be placed on the top surface 226 of the support plate 220. The mold body 222 may then be coupled to one or more brackets 256 via fasteners 258. The bracket 256 may, in turn, be coupled to the support plate 220 by suitable fasteners 260. Further, one or more fluid connectors 262 may fluidly couple the fluid passage 254 defined by the tube 254 to a fluid source (not shown).

After being coupled to the support plate 220, the die body 222 defines a die cavity 234. More specifically, as mentioned above, the top surface 226 of the support plate 220 defines a shape corresponding to a cross-section of a portion of the die cavity 234. For example, the top surface 226 of the support plate 220 may have the same or similar shape as the cross-sectional shape of the die cavity 234. As such, coupling the die body 222 to the support plate 220 conforms the die body 222 to the shape of the top surface 226 of the support plate 220. In several embodiments, as shown in fig. 18, the die body 222 is planar or otherwise flat prior to coupling to the support plate 220. As such, coupling the die body 222 to the support plate 220 may deform or otherwise bend the die body 222 to conform to the shape of the top surface 226 of the support plate 220. After such deformation, a top surface 246 of the top plate 240 of the mold body 222 (which defines the same shape or a similar shape as the top surface 226 of the support plate 220) defines the mold cavity 234.

Referring now to fig. 20 and 21, the mold assembly 200 may include a platform 266, the platform 266 being coupled to the top surface 246 of the top plate 240 or otherwise positioned on the top surface 246 of the top plate 240. Generally, the platform 266 is raised relative to the top surface 246 such that portions of the lap joint are formed in the component. As shown, the platform 266 may be formed from a plurality of U-shaped sheets 268 and a plurality of rectangular sheets 270. In several embodiments, the sheets 268, 270 have a stepped configuration to provide a gradual transition between the top 246 of the mold body 22 and the top of the platform 266. The sheets 268, 270 may be adhesively coupled together, welded, or otherwise coupled together in any suitable manner. In one embodiment, the sheets 268, 270 are formed of aluminum. However, the platform 266 can be formed from any suitable number, shape, and/or sheet of material. Further, in some embodiments, the platform 266 may be integrally formed (e.g., 3D printed).

Referring particularly to fig. 20, the mold assembly 200 may include a gasket 264 positioned about its perimeter. Generally, the gasket 264 is configured to provide a seal between the mold body 222 and a thermoplastic sheet placed on the mold body 222 to be formed into a component. In certain embodiments, the gasket 264 is used when forming a component from reinforced thermoplastic sheets (e.g., fiberglass). For example, in one embodiment, the gasket 264 may be formed of silicone. However, the gasket 264 may be formed of any other suitable material.

Additionally, the top plate 240 of the mold body 222 may define one or more grooves 272 in the top surface 246 thereof. More specifically, groove 272 is in fluid communication with mold cavity 234. In addition, the groove 272 is also in fluid communication with a vacuum source (not shown) via one or more vacuum ports 274 defined by the mold body 222. In this regard, the groove 272 is configured to provide a vacuum to the mold cavity 234 that causes the thermoplastic sheet to adhere to the top surface 246 of the mold body 222. In the illustrated embodiment, the grooves 272 have a grid-like configuration. However, in alternative embodiments, the groove 272 may have any other suitable configuration and/or be present on any portion of the mold body 222. Further, the vacuum port 274 is illustrated as being positioned proximate to an edge of the mold body 222. However, the vacuum port 274 may be positioned in any other suitable location of the mold body 222.

In certain embodiments, the mold assemblies 100 and/or 200 may be incorporated into or otherwise combined with other types of mold assemblies or mold assembly portions. For example, mold assemblies 100 and/or 200 may be used to form a portion of rotor blade 22 proximate to a midspan portion of rotor blade 22, while another mold assembly having a different configuration (e.g., a mold assembly for which mold cavities need to be machined) may be used to form a portion of rotor blade 22 located proximate to a tip of rotor blade 22. Additionally, the mold assembly 100 may be used to form a first portion of a component and the mold assembly 200 may be used to form a second portion of the component. However, the mold assemblies 100, 200 may be used separately to form the component.

Further, various aspects of one of the mold assemblies 100, 200 may be combined or otherwise incorporated into the other of the mold assemblies 100, 200. For example, one or more of the top plates 240 may be placed on the top surface 132 of the mold body 122 of the mold assembly 100. However, in other embodiments, the top plate 240 or other sheet metal-like member is not placed on the top surface 132 of the mold body 122 of the mold assembly 100.

Fig. 22 illustrates one embodiment of a method 300 for creating a vacuum forming mold assembly in accordance with aspects of the present subject matter. Although fig. 22 depicts steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement. As such, various steps of the methods disclosed herein may be omitted, rearranged, combined, and/or adapted in various ways without departing from the scope of the present disclosure.

As shown in fig. 22, at (302), the method 300 includes forming a plurality of support plates. For example, the plurality of support plates 120, 220 may be formed, such as via water jet cutting. As discussed in more detail above, after being formed, the top surface 126, 226 of the support plate 120, 220 defines a shape corresponding to a cross-section of at least a portion of the die cavity 128, 234.

At (304), the method 300 includes removably coupling a mold body to a plurality of support plates to form a mold assembly. For example, in one embodiment, the plurality of mold body segments 130 may be coupled to the support plate 120 via brackets 154 and fasteners 146, 156. Once coupled to the support plates 120, the die body segments 130 conform to the shape of the top surface 126 of each support plate 120 such that the die body 122 defines a die cavity 128. In another embodiment, the mold body 222 (which may include the base plate 238, the top plate 240, and/or the tubes 254) may be coupled to the plurality of support plates 222 using the bracket 256 and the fasteners 258, 260. Once coupled to the support plates 220, the die body 222 conforms to the shape of the top surface 226 of each support plate 220 such that the die body 222 defines a die cavity 234.

The mold assemblies 100, 200 and associated methods 300 for producing the mold assemblies 100, 200 provide advantages over conventional vacuum forming molds and methods of forming such molds. For example, as described above, the support plates 120, 22 include top surfaces 126, 226, the top surfaces 126, 226 defining a shape corresponding to a cross-sectional shape of the die cavities 128, 234. As such, the mold body 122, 222 conforms to the top surfaces 126, 226 (e.g., via deformation) such that the mold body 122, 222 defines the mold cavity 128, 234. In this regard, and unlike conventional vacuum forming molds and methods of forming such molds, the mold assemblies 100, 200 and associated methods 300 do not require machining to form the mold cavities 128, 234. Accordingly, the mold assemblies 100, 200 are less expensive to produce than conventional mold assemblies, thereby reducing the overall cost of the wind turbine.

This written description uses examples to disclose the technology, including the best mode, and also to enable any person skilled in the art to practice the technology, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the technology is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.