阅读说明：本技术 模具部分的连接 (Joining of mould parts ) 是由 K·莱曼马德森 于 2019-02-01 设计创作，主要内容包括：公开了一种用于风力涡轮机叶片的部件的制造的方法、模具系统和用于模具系统的模具部分。模具部分(100)可以具有模制表面(102),该模制表面(102)具有第一级侧区段(104)、第二级侧区段(106)以及在第一级侧区段与第二级侧区段之间的中心部分(108)。模具部分具有被配置成邻接第二模具部分的第二级连接界面(112)的第一级连接界面(110)。第一级连接界面包括基本上垂直于模制表面的第一级连接表面。第一级连接界面包括被配置成连接到真空源的出口(116)。第一级连接包括围绕出口的密封路径,所述路径包括用于密封糊剂(144)的斜角边缘。(A method for manufacturing a component for a wind turbine blade, a mould system and a mould part for a mould system are disclosed. The mold portion (100) may have a molding surface (102), the molding surface (102) having a first level side section (104), a second level side section (106), and a central portion (108) between the first level side section and the second level side section. The mold portion has a first level connection interface (110) configured to abut a second level connection interface (112) of a second mold portion. The first level connection interface includes a first level connection surface substantially perpendicular to the molding surface. The first level connection interface includes an outlet (116) configured to connect to a vacuum source. The first level of connection includes a sealing path around the outlet, the path including a beveled edge for a sealing paste (144).)

1. A mould part of a mould system for the manufacture of a component of a wind turbine blade,

the mold portion having a molding surface with a first level side section, a second level side section, and a central portion between the first level side section and the second level side section,

the mold portion having a first level connection interface configured to abut a second level connection interface of a second mold portion,

the first level connection interface includes a first level connection surface,

the first level connection interface includes an outlet configured to connect to a vacuum source,

the first level connection interface includes a sealed path surrounding the outlet, and wherein the sealed path includes a sealed portion formed by a beveled edge between the molding surface and the first level connection surface, the sealed portion configured to receive a sealant paste.

2. The mold section of claim 1 wherein the central portion is substantially flat.

3. The mold section of claim 2, the first stage side section comprising a first stage base portion and a first stage ramp portion, the first stage base portion being substantially parallel to the central portion, the first stage ramp portion joining the central portion and not parallel to the central portion, the second stage side section comprising a second stage base portion and a second stage ramp portion, the second stage base portion being substantially parallel to the central portion, the second stage ramp portion joining the central portion and not parallel to the central portion.

4. The mold section of any of the preceding claims wherein the sealing path comprises a first sealing portion comprising a recess for receiving a gasket material.

5. The mold section of claim 4, wherein the first sealing portion extends from the first stage side section to the second stage side section.

6. The mold section of any of claims 4-5, wherein the first sealing portion is offset from the central portion by a distance of between 1-50 mm.

7. The mold section of any of the preceding claims wherein a beveled edge of the sealing portion is between the first stage side section of the molding surface and the first stage connecting surface.

8. The mold section of any of the preceding claims wherein a beveled edge of the sealing portion is between the second stage side section of the molding surface and the first stage connecting surface.

9. The mould section according to any preceding claim wherein the first stage connection interface comprises one or more bolts and/or bolt holes extending through the first stage connection surface.

10. The mold section of claim 9, wherein the one or more bolts and/or bolt holes are surrounded by one or more fifth seal sections.

11. A mould system for the manufacture of a component of a wind turbine blade, the mould system comprising:

-a first mould part having a first moulding surface with a first stage side section, a first second stage side section and a first central portion between the first stage side section and the first second stage side section, the first mould part having a first stage connection interface comprising a first stage connection surface, the first stage connection interface comprising a first outlet configured to be connected to a vacuum source,

-a second mould part having a second moulding surface with a second first level side section, a second level side section and a second central portion between the second first level side section and the second level side section, the second mould part having a second level connection interface comprising a second level connection surface,

the first level connection interface is configured to abut the second level connection interface,

the first and/or second level connection interfaces comprise a sealing path configured to surround the outlet, and wherein the sealing path comprises a sealing portion formed by a beveled edge between the first molding surface and the first level connection surface and/or a beveled edge between the second molding surface and the second level connection surface, the sealing portion configured to receive a sealant paste.

12. A method for assembling a mould system for the manufacture of components of a wind turbine blade, the mould system comprising:

-a first mould part having a first moulding surface with a first stage side section, a first second stage side section and a first central portion between the first stage side section and the first second stage side section, the first mould part having a first stage connection interface comprising a first stage connection surface, the first stage connection interface comprising a first outlet configured to be connected to a vacuum source,

-a second mould part having a second moulding surface with a second first level side section, a second level side section and a second central portion between the second first level side section and the second level side section, the second mould part having a second level connection interface comprising a second level connection surface,

the first and/or second level connection interfaces comprising a sealing path configured to surround the outlet and wherein the sealing path comprises a sealing portion formed by a beveled edge between the first molding surface and the first level connection surface and/or a beveled edge between the second molding surface and the second level connection surface,

the method comprises the following steps:

-positioning the first and second mould parts such that the first level connection interface abuts the second level connection interface,

-applying a sealant paste to the sealing portion of the sealing path,

-applying a first negative pressure to the first outlet by the vacuum source.

13. The method of claim 12, wherein the mold system is used for Vacuum Assisted Resin Transfer Molding (VARTM) of the component by applying a second negative pressure between a seal layer and the first and second molding surfaces, and wherein the first negative pressure is lower than the second negative pressure.

14. A method for manufacturing a component for a wind turbine blade, comprising:

-positioning a first mould part and a second mould part such that a first level connection interface of the first mould part abuts a second level connection interface of the second mould part;

-applying a first negative pressure between the first level connection interface and the second level connection interface;

-applying a second underpressure between the sealing layer and the first and second moulding surfaces, and wherein the first underpressure is lower than the second underpressure.

15. The method of claim 14, wherein the first negative pressure is a predetermined fraction of the second negative pressure.

16. The method of claim 15, wherein the predetermined fraction is between 10-70 percent.

17. The method according to any of claims 14-16, wherein the second negative pressure is between 10-500 mbar.

18. The method according to any of claims 14-17, wherein the first negative pressure is between 0.1-200 mbar.

Technical Field

The present disclosure relates to the connection of mould parts of a mould to form a mould for moulding of a component of a wind turbine blade (such as a shell part or a shear web, such as an I-web or C-web), in particular for vacuum assisted resin transfer.

Background

Wind turbine blades are typically assembled from multiple components. For example, a typical wind turbine blade is manufactured by molding individual shell halves, shear webs, and the like.

Wind turbine blades are typically reinforced by adding shear webs on the inside of the wind turbine blade along the length of the wind turbine blade. The shear web may be formed, for example, in the shape of an I-beam (i.e., I-web) or in the shape of a C (i.e., C-web).

The shear web may be almost as long as the wind turbine blade. Thus, the mould for moulding the shear web may be in excess of 70 metres in length. The mould may be segmented, in particular in the longitudinal or spanwise direction of the mould. The segmented mold may be assembled such that the shear web may be manufactured as a unitary structure.

In using a vacuum assisted resin transfer molding process, the mold should preferably be airtight. Thus, in molds using segments, the interface between the segments may be a potential source of the formation of leaks.

Disclosure of Invention

It is an object of the present disclosure to provide a method and a device for eliminating or at least reducing the formation of leaks in segmented molds using molding for components of wind turbine blades, such as shear webs or shell parts, in particular in Vacuum Assisted Resin Transfer Molding (VARTM).

Accordingly, the present invention relates to a mould part, such as a first mould part, for a mould system, such as a mould system for the manufacture of a component of a wind turbine blade.

The mold portion has a molding surface with a first level side section, a second level side section, and a central portion between the first level side section and the second level side section.

The mold portion has a first level connection interface configured to abut a second level connection interface of a second mold portion. The mold section may have a second level connection interface configured to abut the first level connection interface of the third level mold section.

The primary connection interface includes a primary connection surface (e.g., substantially perpendicular to the molding surface). The second level connection interface may comprise a second level connection surface (e.g. substantially perpendicular to the moulding surface). The second level connection surface may be opposite the first level connection surface.

The first level connection interface includes an outlet configured to connect to a vacuum source (such as a vacuum source of a mold system).

A mould system, such as a mould system for the manufacture of a component of a wind turbine blade, is also disclosed. The mold system includes a first mold portion, such as the disclosed mold portion, and a second mold portion, such as the disclosed mold portion.

The first mold portion has a first molding surface with a first level side section, a first second level side section, and a first central portion between the first level side section and the first second level side section.

The first mold portion has a first level connection interface that includes a first level connection surface (e.g., substantially perpendicular to the first molding surface). The first-level connection interface includes a first outlet configured to connect to a vacuum source (such as a vacuum source of a mold system). The first mold portion may have a first second level connection interface that includes a first second level connection surface (e.g., substantially perpendicular to the first molding surface). The first second level connection surface may be opposite the first level connection surface.

The second mold portion has a second molding surface with a second first level side section, a second level side section, and a second central portion between the second first level side section and the second level side section.

The second mold portion has a second level connection interface that includes a second level connection surface (e.g., substantially perpendicular to the second molding surface). The second mold portion may have a second first level connection interface that includes a second first level connection surface (e.g., substantially perpendicular to the second molding surface). The second first level connection surface may be opposite the second level connection surface. The second first-level connection interface may include a second outlet configured to connect to a vacuum source (such as a vacuum source of a mold system).

The first level connection interface is configured to abut the second level connection interface. The first second level connection interface may be configured to abut a third first level connection interface of a third mold portion. The second first level connection interface may be configured to abut a fourth second level connection interface of a fourth mold portion.

Also disclosed is a method for assembling a mould system, such as a mould system for the manufacture of a component of a wind turbine blade, such as the disclosed mould system. Wherein the mold system comprises a first mold portion and a second mold portion.

The method comprises the following steps: the first and second mold portions are positioned such that the first level connection interface abuts the second level connection interface, and a first negative pressure is applied to the first outlet by a vacuum source (such as a vacuum source of a mold system), such as to create a negative pressure between the first level connection interface and the second level connection interface.

A method for manufacturing a component for a wind turbine blade is also disclosed. The method comprises the following steps: positioning the first mold portion and the second mold portion such that the first level connection interface of the first mold portion abuts the second level connection interface of the second mold portion; applying a first negative pressure between the first level connection interface and the second level connection interface; and applying a second negative pressure between the sealing layer and the first and second molding surfaces. The first negative pressure may be lower than the second negative pressure.

In connecting multiple mold sections to form a complete mold or mold system, there is an increased risk that the complete mold surface may not be completely airtight. In particular, the interface between the mould parts provides an area of increased risk of leakage. The present disclosure provides a way to connect mold sections by applying a low pressure or vacuum in the interface between the connected mold sections.

One advantage of the present disclosure is that a tighter (e.g., more air tight) connection between the mold sections may be achieved.

Furthermore, the present disclosure provides the advantage that air may be reduced and/or prevented from entering the molding process in case of leakage. Thereby, the resulting component may be of higher quality and the rate of defective components from the manufacturing process may be reduced.

The component may be a shear web or the component may be a shell portion. The mould system and/or mould part(s) may be used for the manufacture of a shear web of a wind turbine blade. Alternatively, the mould system and/or mould part(s) may be used for the manufacture of shell parts (such as half shells) of wind turbine blades.

The mould system and/or mould part(s) may be used for Vacuum Assisted Resin Transfer Moulding (VARTM) of the component, such as by applying a second negative pressure between the sealing layer and the moulding surface, such as the first moulding surface and/or the second moulding surface. The first negative pressure may be lower than the second negative pressure. For example, the first negative pressure may be set to a lower negative pressure than the second negative pressure. By providing a lower pressure in the interface between the mould parts, in case of any leakage, resin is extracted from the moulding process and into the interface, rather than air being sucked from the interface and into the moulding process. The first negative pressure may be a predetermined fraction of the second negative pressure. For example, the first negative pressure may be adapted to be a predetermined fraction of the second negative pressure. The predetermined fraction may be between 0.1-90 percent, such as between 20-80 percent, such as between 50-75 percent. The second underpressure may be between 10-500mbar, such as between 10-300 mbar, such as between 100-300 mbar, or such as between 10-50 mbar. The first underpressure may be between 0.1 and 200 mbar, such as between 0.1 and 100 mbar, such as between 0.1 and 50 mbar. The difference between the first and second sub-pressures may be greater than 1 mbar, such as greater than 10 mbar, such as greater than 50 mbar.

It will be understood that any feature explained in relation to one aspect of the present disclosure also applies to any other aspect of the present disclosure. For example, it will be understood that any feature explained with respect to any mold portion may be applied to a mold portion of the disclosed method or mold system, such as the first mold portion and/or the second mold portion.

The central portion may be substantially flat, such as for moulding of a shear web. Alternatively, the central portion may be arcuate in shape, such as for molding of housing portions such as half shells.

Side sections, such as primary side sections and/or secondary side sections, may include a base portion and/or a ramp (ramp) portion. For example, the first stage side section may comprise a first stage base portion and/or a first stage ramp portion. Alternatively, or additionally, the second stage side section may comprise a second stage base portion and/or a second stage ramp portion. The side section may be configured for adhering the sealing layer to allow application of a second negative pressure between the sealing layer and the molding surface (such as the first molding surface and/or the second molding surface). The sealing layer may be adhered to the side section by using a double-sided tape (such as a sealant tape).

The base portion(s), such as the first stage base portion and/or the second stage base portion, may be substantially parallel to the central portion. The base portion(s) may be positioned at a lower (vertical) level than the central portion. Ramp portion(s), such as first stage ramp portions and/or second stage ramp portions, may engage the central portion and/or the base portion. The ramp portion(s), such as the first stage ramp portion and/or the second stage ramp portion, may not be parallel to the central portion, such as substantially perpendicular to the central portion.

The outlet may extend through the first stage connecting surface. Whereby a vacuum source may be attached to the outlet, e.g. from behind the first level connection surface, to allow pressure to be applied to a cavity formed between the first level connection surface of the first connection interface of the first mould part and the second level connection surface of the second connection interface of the second mould part.

The first level connection interface and/or the second level connection interface may include a sealed pathway. The sealed path may surround the outlet. Thereby, the pressure in the cavity formed by the first level connecting surface of the first connecting interface of the first mould part and the second level connecting surface of the second connecting interface of the second mould part can be reduced more effectively in case a vacuum source is attached to the outlet.

The sealing path may comprise a plurality of sealing portions, for example comprising a first sealing portion, a second sealing portion, a third sealing portion and/or a fourth sealing portion. For example, the sealing path may include a first sealing portion, a second sealing portion, a third sealing portion, and/or a fourth sealing portion.

The sealing portion (such as the first sealing portion and/or the fourth sealing portion) of the sealing path may be substantially parallel to the central portion. The first seal portion may extend from the first stage side section to the second stage side section, such as from the first stage ramp portion to the second stage ramp portion. The fourth seal portion may extend from the first stage side section to the second stage side section, such as from a first stage (e.g., left) outer perimeter of the first stage connecting surface to a second stage (e.g., right) outer perimeter of the first stage connecting surface.

The sealing path and/or a sealing portion of the sealing path (such as the first sealing portion and/or the fourth sealing portion) may comprise a recess for receiving a gasket material, such as an elastic gasket material, such as a rubber gasket material. The liner material may be removable from the recess. For example, the gasket material may be removed to allow cleaning and/or replacement.

The first sealing portion may be offset from the central portion by a distance, such as a distance greater than 1 mm, such as a distance between 1-50mm, such as between 5-40 mm, such as between 10-25 mm.

The fourth seal portion may be offset from the bottom periphery of the first stage connecting surface by a distance, such as a distance greater than 1 mm, such as a distance between 1-50mm, such as between 5-40 mm, such as between 10-25 mm.

The sealing path and/or a sealing portion of the sealing path (such as the second sealing portion and/or the third sealing portion) may be configured to receive a sealant paste. For example, the sealing path and/or a sealing portion of the sealing path (such as the second sealing portion and/or the third sealing portion) may be formed by a beveled edge (such as a beveled edge configured to receive a sealant paste). The sealing portion (such as the second sealing portion and/or the third sealing portion) of the sealing path may be formed, for example, by a beveled edge (such as a beveled edge configured to receive the sealant paste) between the molding surface and the primary connecting surface (such as between the first stage side section and the first stage connecting surface and/or between the second stage side section and the first stage connecting surface). For example, the second sealing portion may be between the first stage side section and the first stage connecting surface, and/or the third sealing portion may be between the second stage side section and the first stage connecting surface. The utilization of a sealing path configured for receiving a sealant paste and/or a sealing portion of the sealing path (such as a beveled edge) may be particularly advantageous for surfaces on which the sealing layer is intended to adhere for the application of a second negative pressure between the sealing layer and a molding surface (such as a first molding surface and/or a second molding surface). For example, a sealant paste received in such a sealing path or in a sealing portion of such a sealing path (such as in the second sealing portion and/or the third sealing portion) may be configured to be coupled to a sealant tape adhered to the sealing layer. Thereby, the connection of the mould parts reduces the risk of leakage at and around the interface between the sealing layers.

The method may include applying a sealant paste to a sealing portion of the sealing path, the sealing portion (such as the second sealing portion and/or the third sealing portion) configured to receive the sealant paste.

The first stage connection interface may include one or more bolts and/or bolt holes (e.g., extending through the first stage connection surface). Bolts and/or bolt holes may provide fastening of the first level connection interface to the second level connection interface of the second mold portion. The second stage connection interface may include one or more bolts and/or bolt holes, such as to facilitate fastening to the first stage connection interface of the third mold.

The one or more bolts and/or bolt holes may be surrounded by one or more fifth sealing portions. Thereby, leakage caused by the bolts and/or bolt holes may be reduced, facilitating a more efficient pressurization of the cavity formed between the first stage connecting surface and the second stage connecting surface of the second stage connecting interface of the second mould part.

Drawings

Embodiments of the present disclosure will be described in more detail below with respect to the accompanying drawings. The drawings illustrate one way of implementing the invention and should not be construed as limiting other possible embodiments falling within the scope of the set of appended claims.

FIG. 1 is a schematic view illustrating an exemplary wind turbine,

FIG. 2 is a schematic view illustrating an exemplary wind turbine blade,

FIG. 3 is a schematic diagram illustrating a cross-section of an exemplary wind turbine blade,

figure 4 is a schematic diagram illustrating an exemplary mold portion,

figure 5 is a schematic diagram illustrating an exemplary mold system,

figure 6 is a schematic diagram illustrating an exemplary connection interface,

figure 7 is a schematic diagram illustrating an exemplary connection interface,

FIG. 8 is a flow chart of an exemplary method.

Detailed Description

Fig. 1 illustrates a conventional modern upwind wind turbine 2 according to the so-called "danish concept" having a tower 4, a nacelle 6 and a rotor with a substantially horizontal rotor shaft. The rotor comprises a hub 8 and three blades 10 extending radially from the hub 8, each blade 10 having a blade root portion 16 closest to the hub and a blade tip portion 14 furthest from the hub 8.

FIG. 2 shows a schematic view illustrating a wind turbine blade 10. The wind turbine blade 10 has the shape of a conventional wind turbine blade and comprises a root region 30 closest to the hub, a profile or airfoil region 34 furthest away from the hub and a transition region 32 between the root region 30 and the airfoil region 34. When the blade is mounted on the hub, the blade 10 comprises a front edge 18 facing in the direction of rotation of the blade 10, and a rear edge 20 facing in the opposite direction to the front edge 18.

The airfoil region 34 (also called contour region) has an ideal or almost ideal blade shape with respect to generating lift, whereas the root region 30 has a substantially circular or elliptical cross-section due to structural considerations, which for example makes it easier and safer to mount the blade 10 to the hub. The diameter (or chord) of the root region 30 may be constant along the entire root region 30. The transition zone 32 has a transition profile gradually changing from the circular or elliptical shape of the root zone 30 to the airfoil profile of the airfoil zone 34. The chord length of the transition zone 32 typically increases with increasing distance r from the hub. The airfoil region 34 has an airfoil profile with a chord extending between the leading edge 18 and the trailing edge 20 of the blade 10. The width of the chord decreases with increasing distance r from the hub.

The shoulder 40 of the blade 10 is defined as the location where the blade 10 has its maximum chord length. The shoulder 40 is typically provided at the interface between the transition region 32 and the airfoil region 34.

It should be noted that chords of different sections of the blade typically do not lie in a common plane, as the blade may be twisted and/or curved (i.e. pre-curved), thus providing a chord plane with a correspondingly twisted and/or curved stroke, which is most often the case in order to compensate for the local velocity of the blade depending on the radius from the hub.

The blade is typically made of a pressure side shell part 36 and a suction side shell part 38, which pressure side shell part 36 and suction side shell part 38 are glued to each other along a bonding line at the leading edge 18 and trailing edge of the blade 20.

Fig. 3 shows a schematic diagram illustrating a cross-section of the blade along the line I-I shown in fig. 2. As previously described, the blade 10 may include a pressure side shell portion 36 and a suction side shell portion 38. The pressure side shell portion 36 includes a spar cap 41, also referred to as a main laminate, which constitutes a load carrying portion of the pressure side shell portion 36. The spar cap 41 comprises a plurality of fibre layers 42, which fibre layers 42 mainly comprise unidirectional fibres aligned in the longitudinal direction of the blade in order to provide stiffness to the blade. The suction side shell part 38 also comprises a spar cap 45, said spar cap 45 comprising a plurality of fibre layers 46. The pressure side shell portion 38 may also include a sandwich core material 43, typically made of balsa wood or foamed polymer, sandwiched between a plurality of fiber reinforced skins. The sandwich core material 43 serves to provide stiffness to the shell in order to ensure that the shell substantially maintains its aerodynamic profile during rotation of the blade. Similarly, the suction side shell portion 38 may also include an interlayer core material 47.

The spar caps 41, 45 of the pressure side shell part 36 and the suction side shell part 38 are connected via first and second shear webs 50, 55. The shear webs 50, 55 are shaped in the illustrated embodiment as substantially I-shaped webs. The first shear web 50 comprises a shear web body and two web foot flanges. The shear web body comprises a sandwich core material 51, such as balsa wood or foamed polymer, covered by a plurality of skin layers 52, the skin layers 52 being made of a plurality of fibre layers. The second shear web 55 is of similar design, having a shear web body comprising a sandwich core material 56 covered by a plurality of skin layers 57, the plurality of skin layers 57 being made of a plurality of fibre layers, and two web foot flanges.

The sandwich core material 51, 56 of the two shear webs 50, 55 may be chamfered (chamferred) near the flanges in order to transfer loads from the webs 50, 55 to the primary laminates 41, 45 without risk of failure and fracture at the joint between the shear web body and the web foot flange. However, such a design will typically result in a resin rich region in the joint area between the leg and the flange. Furthermore, such resin-rich areas may comprise resin that has burned due to high exothermic peeking during the curing process of the resin, which in turn may lead to mechanical weakness. To compensate for this, a plurality of filler strings 60 comprising glass fibers are typically arranged at these junction areas. Furthermore, such cords 60 may also facilitate transferring loads from the skin of the shear web body to the flange. However, alternative construction designs are possible.

The blade shells 36, 38 may comprise additional fibre reinforcement at the leading and trailing edges. Typically, the housing portions 36, 38 are bonded to one another via glue flanges in which additional filler strings (not shown) may be used. Additionally, very long blades may comprise segment sections with additional spar caps connected via one or more additional shear webs.

The shear web may extend over a majority of the length of the wind turbine blade. Thus, the shear web may be in excess of 70 metres in length. Thus, the shear web mould required to manufacture the shear web may require more than 70 metres in length. To facilitate transport and/or storage of such a shear web mould, it may be divided into several sections, i.e. mould sections, of about 10-12 metres in length, which are assembled together to form a complete, e.g. > 70 metres long, shear web mould or mould system.

4-7 illustrate examples of mold sections and mold systems configured for manufacturing shear webs for wind turbine blades. However, it will be appreciated that the concepts described may be similarly applied to mould systems and/or mould parts shaped to mould other components of a wind turbine blade, such as a blade shell mould.

Fig. 4 is a schematic diagram illustrating an exemplary mold portion 100, such as a shear web mold portion. The mould part 100 may be a first mould part and/or a second mould part of a mould system, such as a shear web mould system for the manufacture of a shear web of a wind turbine blade.

Mold portion 100 has a molding surface 102. The molding surface 102 faces substantially upwards, such as to provide a surface for laying components (such as glass fibers for a shear web).

The molding surface 102 includes a first stage side section 104, a second stage side section 106, and a central portion 108. The central portion 108 is between the first stage side section 104 and the second stage side section 106. The central portion 108 is substantially flat. However, if it is envisaged that the mould part 100 is used for moulding of another component of a wind turbine blade, the central portion 108 may have been formed differently, for example the central portion may be curved, for example having a semi-circular cross-section.

The first stage side section 104 includes a first stage base portion 118 and a first stage ramp portion 120. The first stage base portion 118 is substantially parallel to the central portion 108. The first stage ramp 120 partially joins the central portion 108 and the first stage base portion 118. The first level ramp portion 120 is not parallel to the central portion 108. The first stage base portion 118 and the central portion 108 are located at different levels, and the first stage ramp portion 120 joins the central portion 108 and the first stage base portion 118. The first level slope portion 120 may be substantially vertical.

The second stage side section 106 includes a second stage base portion 122 and a second stage ramp portion 124. The second stage base portion 122 is substantially parallel to the central portion 108. The second stage ramp 124 partially joins the central portion 108 and the second stage base portion 122. The second step slope portion 124 is not parallel to the central portion 108. The second stage base portion 122 and the central portion 108 are located at different levels, and the second stage ramp portion 124 joins the central portion 108 and the second stage base portion 122. The second grade slope portion 124 may be substantially vertical.

Mold portion 100 has a first level connection interface 110 and a second level connection interface 112. The second level connection interface 112 is opposite the first level connection interface 110. The connection interfaces 110, 112 are configured to abut corresponding connection interfaces of other mold portions of the mold system. For example, first level connection interface 110 is configured to abut second level connection interface 112 '(see fig. 5) of second mold portion 100'.

For some mold portions, such as mold portions configured to form an end of a mold system, the first level connection interface 110 or the second level connection interface 112 may be omitted or replaced with an end section.

The primary connection interface 110 includes a primary connection surface 114. The first level connection surface 114 is substantially perpendicular to the molding surface 102. First stage connecting surface 114 is substantially perpendicular to the longitudinal direction of mold portion 100 and/or the mold system.

The first stage connection interface 110 includes an outlet 116. The outlet 116 extends through the first stage connecting surface 114. The outlet 116 is configured to be connected to a vacuum source, such as a compressor. By connecting the outlet 116 to a vacuum source, a low pressure can be applied between the mold sections. Thereby, the mould parts may be held together and a tighter seal between the mould parts may be achieved, thereby facilitating moulding of a higher quality shear web and providing a simpler and faster manufacturing process.

The first level connection interface 110 includes a sealed pathway 130. The sealing path 130 may be provided for adding a sealant, such as to provide a hermetic (or near hermetic) seal between the first level connection surface 114 and the second level connection surface of the second mold portion. A sealed path 130 surrounds the outlet 116. For example, the sealing path 130 substantially follows the perimeter of the first stage connection surface 114. The sealing path 130 includes a first sealing portion 132. The seal path 130 will be described in more detail below, for example, with respect to fig. 6.

The first stage connection interface 110 includes one or more bolt and/or bolt holes 126. A bolt and/or bolt-hoe may extend through first-level attachment surface 114. The second stage connection interface 112 includes corresponding bolts and/or bolt holes that may extend through the second stage connection surface 115. Accordingly, bolts and/or bolt holes are provided to attach the first stage connection interface 110 of the first mold portion to the second stage connection interface of the second mold portion.

FIG. 5 is a schematic diagram illustrating an exemplary mold system 200 (such as a shear web mold system for the manufacture of a shear web of a wind turbine blade). Mold system 200 includes a first mold portion 100 and a second mold portion 100'. Although not shown, the mold system 200 may include more than two mold sections, such as three, four, five, six, seven, eight, or more mold sections.

The first mold portion 100 is described in more detail with respect to fig. 4. The second mold portion 100' may be similar to the first mold portion 100 as described in more detail with respect to fig. 4.

As can be seen, first level connection interface 110 of first mold portion 100 abuts and connects to second level connection interface 112 'of second mold portion 100'.

A third mold portion (not shown) may be connected to first mold portion 100 through a second connection interface 112 connected to first mold portion 100.

A fourth mold portion (not shown) may be connected to second mold portion 100' via a first level connection interface 110' connected to second mold portion 100 '.

FIG. 6 is a schematic diagram illustrating an exemplary connection interface.

The first level connection interface 110 includes a sealed pathway 130. A sealed path 130 surrounds the outlet 116. For example, the sealing path 130 substantially follows the perimeter of the first stage connection surface 114.

The sealing path 130 includes a first sealing portion 132. The first sealing portion 132 includes a recess for receiving a gasket material. The first seal portion 132 is substantially parallel to the central portion 108. The first seal portion extends from the first stage side section 104 to the second stage side section 106, such as from the first stage ramp portion 120 to the second stage ramp portion 124. The first seal portion 132 is offset from the central portion 108 by a distance of between 1-50mm, for example. This offset may provide a better seal, particularly when using a gasket material.

The sealing path 130 includes a second sealing portion 134. The second seal portion 134 is formed by a beveled edge between the molding surface and the primary connecting surface 114, such as between the primary side section 104 and the primary connecting surface 114 as shown. The second sealing portion 134 is configured to receive the sealant paste, such as by a beveled edge.

The sealing path 130 includes a third sealing portion 136. The third seal portion 136 is formed by a beveled edge between the molding surface and the primary connecting surface 114, such as between the secondary side section 106 and the primary connecting surface 114 as shown. The third sealing portion 136 is configured to receive the sealant paste, such as by a beveled edge.

The seal path 130 includes a fourth seal portion 138. The fourth seal portion 138 includes a recess for receiving the gasket material. The fourth seal portion 138 is substantially parallel to the central portion 108. The fourth seal portion 138 extends from the first stage side section 104 to the second stage side section 106. The fourth seal portion 138 is offset from the bottom perimeter of the first stage connecting surface 114 by a distance of, for example, between 1-50 mm. The offset may provide a better seal, particularly when using a gasket material.

The first level connection interface includes fifth sealing portion(s) 140. The fifth sealing portion(s) 140 surrounds the bolt and/or bolt hole 126. The fifth sealing portion(s) may prevent leakage through the bolt hole.

Fig. 7a and 7b are schematic diagrams illustrating an exemplary connection interface.

Fig. 7a is a cross-sectional view of the first level connection interface 110 of fig. 6 taken along line a-a. As shown, the second seal portion 134 is formed by a beveled edge between a first stage side section (such as the first stage base portion 118) and the first stage connecting surface 114. Additionally, as shown, the fourth sealing portion 138 includes a recess for receiving a gasket material. Further illustrated, the fourth seal portion 138 is offset from a bottom perimeter of the first stage connection surface 114.

Fig. 7b shows the first level connection interface 110 of fig. 7a, such as first mold portion 100, being connected to the second level connection interface 112 'of second mold portion 100'.

A gasket material 142 is applied in the recess formed by the fourth seal portion 138. As illustrated, a second level connection interface (such as second level connection interface 112 'of second mold portion 100') need not have a sealing portion to receive gasket material 142. However, in other exemplary mold sections, the second level connection interface may be provided with a sealing portion to receive the gasket material.

The sealant paste 144 is applied in the recess formed by the beveled edge of the second sealing portion 134. As illustrated, a second level connection interface (such as the second level connection interface 112 'of the second mold portion 100') may be provided with a beveled edge to receive the sealing paste 144. In other exemplary mold sections, the second level connection interface may be provided without a beveled edge. In other exemplary mold sections, the first level connection interface may be provided without a beveled edge. Thus, it will be appreciated that beveled edges may be provided in one or both of the connection interfaces to form a recess for receiving the sealant paste 144.

Fig. 8 is a flow diagram of an exemplary method 300, such as a method for assembling a mold system (such as the mold system 200 including the first mold portion 100 and the second mold portion 100' as described above) for the manufacture of a component of a wind turbine blade (such as a shear web or shell portion).

The method 300 includes positioning 302 a first mold portion and a second mold portion such that a first level connection interface (e.g., a first level connection interface) of the first mold portion abuts a second level connection interface (e.g., a second level connection interface) of the second mold portion.

The method further includes applying 303 the sealant paste to a sealing portion of the sealing path, the sealing portion forming a beveled edge between the first molding surface and the first level connection surface and/or a beveled edge between the second molding surface and the second level connection surface. For example, as described above, a sealant paste may be applied 303 to the second seal portion and/or the third seal portion of the sealing path.

The method further includes applying 304 a first negative pressure to an outlet, e.g., a first outlet, of the first mold portion via a vacuum source.

The mould system may be used for Vacuum Assisted Resin Transfer Moulding (VARTM) of a component, for example by applying a second underpressure between the sealing layer and a moulding surface of the mould part, such as a first moulding surface of the first mould part and a second moulding surface of the second mould part.

The first negative pressure applied 304 to the outlet may be lower than the second negative pressure used in the VARTM process. Thereby, it can be ensured that if there is a leak in the interface between the mould parts, resin enters the interface instead of air entering the moulding process.

The invention has been described with reference to the preferred embodiments. However, the scope of the present invention is not limited to the illustrated embodiments, and alterations and modifications can be performed without departing from the scope of the present invention.

REFERENCE LIST

2 wind turbine

4 tower frame

6 nacelle

8 hub

10 blade

14 blade tip

16 blade root

18 front edge

20 rear edge

30 root zone

32 transition zone

34 wing area

36 pressure side shell

38 suction side shell

40 shoulder

41 spar cap

42 fiber layer

43 Sandwich core Material

45 spar cap

46 fiber layer

47 sandwich core material

50 first shear web

51 Sandwich core Material

52 surface layer

55 second shear web

56 sandwich core material

57 surface layer

60 filling rope

100 shear web mold section

102 molding surface

104 first stage side section

106 second stage section

108 center part

110 first level connection interface

112 second level connection interface

114 first level connection surface

115 second-stage connecting surface

116 outlet port

118 first stage base section

120 first grade slope part

122 second stage base portion

124 second grade slope portion

126 bolt(s)

128 bolt hole(s)

130 sealing the path

132 sealing part

134 second seal portion

136 third seal portion

138 fourth seal portion

140 fifth seal portion(s)

142 cushioning material

144 sealing paste

146 first stage mold insert

148 second stage mold insert

200 shear web mold system

300 method

302 positioning a first mold portion and a second mold portion

303 applying a sealant paste

304 applying a first negative pressure