Patent Description:
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. A modern wind turbine typically includes a tower, generator, gearbox, nacelle, and one or more rotor blades. The rotor blades capture kinetic energy from wind using known foil principles and transmit the kinetic energy through rotational energy to turn a shaft coupling the rotor blades to a gearbox, or if a gearbox is not used, directly to the generator. The generator then converts the mechanical energy to electrical energy that may be deployed to a utility grid.

Wind turbine rotor blades generally include a body shell formed by two shell halves of a composite laminate material. The shell halves are generally manufactured using molding processes and then coupled together along the corresponding ends of the rotor blade. In general, the body shell is relatively lightweight and has structural properties (e.g., stiffness, buckling resistance, and strength) which are not configured to withstand the bending moments and other loads exerted on the rotor blade during operation. In addition, wind turbine blades are becoming increasingly longer in order to produce more power. As a result, the blades must be stiffer and thus heavier so as to mitigate loads on the rotor.

To increase the stiffness, buckling resistance, and strength of the rotor blade, the body shell is typically reinforced using one or more structural components (e.g. opposing spar caps with a shear web configured therebetween) that engage the inner surfaces of the shell halves. The spar caps may be constructed of various materials, including but not limited to glass fiber laminate composites and/or carbon fiber laminate composites. Such materials, however, can be difficult to control, defect prone, and/or highly labor intensive due to handling of the dry and pre-preg fabrics and the challenges of infusing large laminated structures.

As such, spar caps may also be constructed of pre-fabricated, pre-cured (i.e. pultruded) composites that can be produced in thicker sections, and are less susceptible to defects. In addition, the use of pultrusions in spar caps can decrease the weight and may also increase the strength thereof. Accordingly, the pultruded composites can eliminate various concerns and challenges associated with using dry fabric alone. As used herein, the terms "pultruded composites," "pultrusions," "pultruded members" or similar generally encompass reinforced materials (e.g. fibers or woven or braided strands) that are impregnated with a resin and pulled through a stationary die such that the resin cures or undergoes polymerization through added heat or other curing methods. As such, the process of manufacturing pultruded composites is typically characterized by a continuous process of composite materials that produces composite parts having a constant cross-section. A plurality of pultrusions can then be joined together to form the spar caps and/or various other rotor blade components.

The benefits of using pultruded plates in spar caps have been realized and spar caps formed using pultrusions usually include pultrusion-formed layers bonded together via a resin material. More specifically, spar caps are generally formed of a plurality of stacked pultruded plates that are bonded together in a mold.

The interface or joint between the spar caps (pultruded or non-pultruded) and shear web is a critical structural interface for both box-beam and I-beam spar constructions. With conventional configurations, this joint relies primarily on the strength of an adhesive or resin deposited at the interface of the components. Event with the benefits of pultruded spar caps, the interface between the spar cap and shear web can be a limiting structural aspect of the blade.

The art is continuously seeking new and improved methods of manufacturing rotor blade components and structural elements with increased strength and decreased weight. A spar configuration wherein pultruded spar caps can also be integrated into an improved structural interface between the spar caps and shear webs would be an advantageous advancement in the art. Examples of prior art documents are <CIT>, <CIT> and <CIT>.

In one aspect, the present disclosure is directed to a rotor blade component for a wind turbine according to claim <NUM> having an improved joint interface configuration. The component includes a first structural component formed from a plurality of stacked pultruded members. This first structural component is a spar cap. A second structural component is fixed to the first structural component at a joint interface. This second structural component is a shear web. One or more webs are used to fix the first and second components together at the joint interface, each of the webs comprising a first section and a second section. In one embodiment, the first section of at least a first one of the plurality of webs extends along and is bonded to a top outer surface of the stacked pultruded members with the second section extending across the joint interface and bonded to the second structural component.

In an additional embodiment, the first section of a second one of the plurality of webs extends along and is bonded to a bottom outer surface of the stacked pultruded members with the second section extending across the joint interface and bonded to the second structural component.

According to the invention, one or more additional ones of the webs has a first section bonded between at least two of the pultruded members in the first structural component and a second section extending across the joint interface and bonded onto or into the second structural component.

In an alternate embodiment, the joint interface may be provided by a plurality of the webs that weave between different ones of the pultruded members in the first structural component with or without the webs that extend along the top or bottom outer surfaces of the stacked pultruded components.

The improved joint interface structure has particular usefulness when configured between a spar cap and a shear web in a box-beam or I-beam spar, wherein the spar cap is formed by the pultruded members and the shear web is a unitary or multi-element component. However, the joint interface structure is not limited to this use or location, and may be used between any structural components within the wind turbine.

The webs may be variously formed. In one embodiment, each web includes one or layers of a woven or non-woven fabric material that is sufficiently pliant to weave around the joint interface or between the pultruded members at the first section and to extend onto or into the second structural member. The fabric layers may be bonded between or to the pultruded members with an adhesive or resin during formation of the first structural member. The fabric material layers may be bonded between the pultruded members during a vacuum thermo-forming process.

In a particular embodiment, the fabric material layers may be impregnated with a resin or adhesive and also serve a primary purpose of adhering or bonding the pultruded members together to form the first structural member. In this embodiment, the webs would extend entirely throughout the width and length of the first structural member between adjacent rows and/or columns of the pultruded members.

The second structural component may be a unitary member, wherein the second section of each of the plurality of webs extends alongside an outer surface of the second structural component. The second sections of multiple webs may overlap along the outer surface of the second structural component.

In an alternate embodiment, the second structural component comprises a plurality of bonded-together components, wherein the second section of at least one of the plurality of webs extends between two or more of the bonded-together components.

The pultruded members may be arranged in various configurations within the first structural component. For example, the pultruded members may be arranged in stacked rows in the first structural component, wherein the first section of at least one of the plurality of webs is bonded between two adjacent stacked rows. The first section of at least one of the webs may be bonded between each of the stacked rows in the configuration.

The pultruded members may be further arranged in adjacent columns within the first structural member, wherein the first section of at least one of the plurality of webs is bonded between the pultruded members at different height positions in adjacent ones of the columns. This web may weave between the columns at a different height between adjacent columns.

It should be appreciated that the first section of a plurality of the webs may weave between any combination of the stacked rows and columns of pultruded members within the first structural component.

In certain embodiments, the first sections of multiple webs may be joined together within the first structural component. Alternatively, the first section of one or more of the webs may include a plurality of branches, wherein each branch extends between different pairs of the pultruded members.

The present disclosure also encompasses a method according to claim <NUM>, for fixing a first structural component comprising a spar cap to a second structural component comprising a shear web at a joint interface within a wind turbine rotor blade with a plurality of webs, wherein the first structural component is formed with a plurality of stacked pultruded members. The method includes bonding a first section of at least one of the plurality of webs onto a top outer surface of the stacked pultruded members and bonding the second section across the joint interface and onto the second structural component. In a further method embodiment, a first section of a second one of the webs is bonded onto a bottom outer surface of the stacked pultruded members and the second section is bonded across the joint interface and onto the second structural component.

According to the invention, the method includes bonding the first section of one or more of the webs between at least two of the pultruded members in the first structural component and bonding the second section across the joint interface and onto or into the second structural component.

In a particular embodiment of the method, the first structural component is a spar cap, and the second structural component is a shear web.

In a certain embodiment, the method includes bonding the second section of each of a plurality of webs alongside an outer surface of the shear web, wherein one or more of the second sections overlap along the outer surface of the shear web.

The pultruded members may be arranged in stacked rows and columns in the spar cap, wherein the method includes weaving the first section of at least one of the plurality of webs between any combination of the stacked rows and columns of pultruded members.

The method may include bonding the first section of at least one of the webs along an outer surface of each of a top and bottom row of the stacked pultruded members. These webs may also extend alongside an outer surface of the second structural member.

These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims.

Generally, the present subject matter is directed to wind turbine rotor blade components having improved joint interfaces, and methods of manufacturing the same. Although not limited to such, the inventive joint interface constructions are particularly useful for the critical structural interface between the shear web and spar caps in a spar configuration. As mentioned, with conventional constructions, this critical interface relies primarily on an adhesive or resin application at the interface between the end of the shear web and the spar cap. The novel joint interface construction in accordance with the present disclosure uses a plurality of webs, for example fabric material webs, that bridge the joint. The webs may be bonded to the outer surfaces of the structural components at the joint interface, and one or more additional webs may be woven between separate members of the structural components, such as between pultruded members of a spar cap. An opposite end section of the webs are bonded along the sides of the shear web or within the shear web, for example between individual structural members forming the shear web. This unique joint interface construction provides a stronger joint capable of transferring larger loads as compared to the conventional construction, which in turn enables lighter and less costly blades or longer blades and blade beam components before reaching material limits, which can reduce the overall cost of electricity produced by the wind turbine.

Referring now to the drawings, <FIG> illustrates a perspective view of a horizontal axis wind turbine <NUM>. It should be appreciated that the wind turbine <NUM> may also be a vertical-axis wind turbine. As shown in the illustrated embodiment, the wind turbine <NUM> includes a tower <NUM>, a nacelle <NUM> mounted on the tower <NUM>, and a rotor hub <NUM> that is coupled to the nacelle <NUM>. The tower <NUM> may be fabricated from tubular steel or other suitable material. The rotor hub <NUM> includes one or more rotor blades <NUM> coupled to and extending radially outward from the hub <NUM>. As shown, the rotor hub <NUM> includes three rotor blades <NUM>. However, in an alternative embodiment, the rotor hub <NUM> may include more or less than three rotor blades <NUM>. The rotor blades <NUM> rotate the rotor hub <NUM> to enable kinetic energy to be transferred from the wind into usable mechanical energy, and subsequently, electrical energy. Specifically, the hub <NUM> may be rotatably coupled to an electric generator (not illustrated) positioned within the nacelle <NUM> for production of electrical energy.

Referring to <FIG>, one of the rotor blades <NUM> of <FIG> is illustrated in accordance with aspects of the present subject matter. In particular, <FIG> illustrates a perspective view of the rotor blade <NUM>, whereas <FIG> illustrates a cross-sectional view of the rotor blade <NUM> along the sectional line <NUM>-<NUM> shown in <FIG>. As shown, the rotor blade <NUM> generally includes a blade root <NUM> configured to be mounted or otherwise secured to the hub <NUM> (<FIG>) of the wind turbine <NUM> and a blade tip <NUM> disposed opposite the blade root <NUM>. A body shell <NUM> of the rotor blade generally extends between the blade root <NUM> and the blade tip <NUM> along a longitudinal axis <NUM>. The body shell <NUM> may generally serve as the outer casing/covering of the rotor blade <NUM> and may define a substantially aerodynamic profile, such as by defining a symmetrical or cambered airfoil-shaped cross-section. The body shell <NUM> may also define a pressure side <NUM> and a suction side <NUM> extending between leading and trailing ends <NUM>, <NUM> of the rotor blade <NUM>. Further, the rotor blade <NUM> may also have a span <NUM> defining the total length between the blade root <NUM> and the blade tip <NUM> and a chord <NUM> defining the total length between the leading edge <NUM> and the trialing edge <NUM>. As is generally understood, the chord <NUM> may vary in length with respect to the span <NUM> as the rotor blade <NUM> extends from the blade root <NUM> to the blade tip <NUM>.

In several embodiments, the body shell <NUM> of the rotor blade <NUM> may be formed as a single, unitary component. Alternatively, the body shell <NUM> may be formed from a plurality of shell components. For example, the body shell <NUM> may be manufactured from a first shell half generally defining the pressure side <NUM> of the rotor blade <NUM> and a second shell half generally defining the suction side <NUM> of the rotor blade <NUM>, with such shell halves being secured to one another at the leading and trailing ends <NUM>, <NUM> of the blade <NUM>. Additionally, the body shell <NUM> may generally be formed from any suitable material. For instance, in one embodiment, the body shell <NUM> may be formed entirely from a laminate composite material, such as a carbon fiber reinforced laminate composite or a glass fiber reinforced laminate composite. Alternatively, one or more portions of the body shell <NUM> may be configured as a layered construction and may include a core material, formed from a lightweight material such as wood (e.g., balsa), foam (e.g., extruded polystyrene foam) or a combination of such materials, disposed between layers of laminate composite material.

Referring particularly to <FIG>, the rotor blade <NUM> may also include one or more longitudinally extending structural components configured to provide increased stiffness, buckling resistance, and/or strength to the rotor blade <NUM>. For example, the rotor blade <NUM> may include a pair of longitudinally extending spar caps <NUM>, <NUM> configured to be engaged against the opposing inner surfaces <NUM>, <NUM> of the pressure and suction sides <NUM>, <NUM> of the rotor blade <NUM>, respectively. Additionally, one or more shear webs <NUM> may be disposed between the spar caps <NUM>, <NUM> so as to form a box-beam spar configuration (<FIG>) or I-beam spar configuration (<FIG>). The spar caps <NUM>, <NUM> are generally designed to control the bending stresses and/or other loads acting on the rotor blade <NUM> in a generally span-wise direction (a direction parallel to the span <NUM> of the rotor blade <NUM>) during operation of a wind turbine <NUM>. Similarly, the spar caps <NUM>, <NUM> may also be designed to withstand the span-wise compression occurring during operation of the wind turbine <NUM>. As mentioned, the joint interface between the spar caps <NUM>, <NUM> and the shear web <NUM> is a critical structural concern.

In <FIG>, the spar caps <NUM>, <NUM> are formed from rows <NUM> (<FIG>) of pultruded members <NUM> that essentially span the chord-wise aspect of the spar cap <NUM>, <NUM>. In <FIG>, the spar caps <NUM>, <NUM> are formed from rows <NUM> (<FIG>) and columns <NUM> (<FIG>) of the pultruded members <NUM>, wherein a plurality of the pultruded members <NUM> span the chord-wise aspect of the spar cap.

It should be understood that the pultruded members <NUM> described herein may be formed using any suitable pultrusion process. For example, the pultruded members <NUM> are generally formed of reinforced materials (e.g. fibers <NUM> or woven or braided strands) that are impregnated with a resin material <NUM> and pulled through a stationary die such that the resin material <NUM> cures or undergoes polymerization through added heat or other curing methods. For example, in certain embodiments, the heated die may include a mold cavity corresponding to the desired shape of pultruded members <NUM> such that the mold cavity forms the desired shape in the completed part. The pultruded members <NUM> may include an outer casing formed using any suitable process, including but not limited to pultrusion, thermoforming, or infusion.

The fibers <NUM> may include but are not limited to glass fibers, nanofibers, carbon fibers, metal fibers, wood fibers, bamboo fibers, polymer fibers, ceramic fibers, or similar. In addition, the fiber material may include short fibers, long fibers, or continuous fibers.

The pultruded members <NUM> may include different or varying materials cured together with the resin material <NUM>. More specifically, the pultruded member 42may include different types of fibers <NUM> arranged in a certain pattern. The fibers may include glass fibers, carbon fibers, or any other suitable fiber material.

Further, the resin material <NUM> may include a thermoplastic material or a thermoset material. A thermoplastic material generally encompasses a plastic material or polymer that is reversible in nature. For example, thermoplastic materials typically become pliable or moldable when heated to a certain temperature and solidify upon cooling. Further, thermoplastic materials may include amorphous thermoplastic materials and/or semi-crystalline thermoplastic materials. For example, some amorphous thermoplastic materials may generally include, but are not limited to, styrenes, vinyls, cellulosics, polyesters, acrylics, polysulphones, and/or imides. More specifically, exemplary amorphous thermoplastic materials may include polystyrene, acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), glycolised polyethylene terephthalate (PET-G), polycarbonate, polyvinyl acetate, amorphous polyamide, polyvinyl chlorides (PVC), polyvinylidene chloride, polyurethane, or any other suitable amorphous thermoplastic material. In addition, exemplary semi-crystalline thermoplastic materials may generally include, but are not limited to polyolefins, polyamides, fluropolymer, ethyl-methyl acrylate, polyesters, polycarbonates, and/or acetals. More specifically, exemplary semi-crystalline thermoplastic materials may include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polypropylene, polyphenyl sulfide, polyethylene, polyamide (nylon), polyetherketone, or any other suitable semi-crystalline thermoplastic material.

Further, a thermoset material generally encompasses a plastic material or polymer that is non-reversible in nature. For example, thermoset materials, once cured, cannot be easily remolded or returned to a liquid state. As such, after initial forming, thermoset materials are generally resistant to heat, corrosion, and/or creep. Example thermoset materials may generally include, but are not limited to, some polyesters, esters, epoxies, or any other suitable thermoset material.

The pultruded members <NUM> can be then joined together to form the spar cap <NUM> via vacuum infusion, adhesive, semi-preg material, pre-preg material, or any other suitable joining method. In this joining process, a first end section of one or more webs <NUM>-<NUM>, such as a flexible fiber material (e.g., glass fiber) web, are woven or interlaced between the pultruded members <NUM>, and an opposite end section of the webs <NUM>-<NUM> extends from the spar cap <NUM>, <NUM> and are attached to the shear web <NUM>, as described in greater detail below.

In addition, it should be understood that the pultruded members <NUM> may have any suitable cross-sectional shape, such as the generally rectangular shape depicted in the figures.

As shown in <FIG>, each of the pultruded members <NUM> may define a single row <NUM>, with multiple rows <NUM> stacked atop one another and joined together as discussed above. It should be understood that the arrangement of the pultruded members <NUM> as shown in the figures is given for illustrative purposes only and is not meant to be limiting. For example, in further embodiments, the spar cap <NUM> may be constructed of a single pultruded member <NUM>. Alternatively, the spar cap <NUM> may be constructed of multiple rows <NUM> and columns <NUM> of the pultruded members <NUM>, as depicted in <FIG> and <FIG>.

Referring to <FIG> and <FIG> in general, a wind turbine rotor blade component <NUM> is depicted in one embodiment as a spar configuration within the blade <NUM>. The component includes a first structural component <NUM> formed from a plurality of stacked pultruded members <NUM>. In a particular embodiment illustrated in the figures, this first structural component <NUM> may be, for example, a spar cap <NUM>, <NUM>. A second structural component <NUM> is fixed to the first structural component <NUM> at a joint interface <NUM>. As illustrated, this second structural component <NUM> may be, for example, a shear web <NUM>. In <FIG>, the first and second components <NUM>, <NUM> form a box-beam spar configuration, and in <FIG> the first and second components <NUM>, <NUM> form an I-beam spar configuration.

Referring to <FIG> in general, one or more webs <NUM>-<NUM> are used to fix the first <NUM> and second <NUM> components together at the joint interface <NUM>. Each of the plurality of webs <NUM>-<NUM> has a first section "a" (i.e., sections <NUM>(a) through <NUM>(a)) and a second section "b" (i.e., sections <NUM>(b) through <NUM>(b)) extending across the joint interface <NUM>. In a first aspect, the present disclosure encompasses an embodiment that utilizes a single web, wherein the first section of this web <NUM>(a) extends along and is bonded to a top outer surface <NUM>(a) of the stacked pultruded members <NUM> and the second section of this web <NUM>(b) extends across the joint interface <NUM> and is bonded (directly or indirectly) to the second structural component <NUM> (e.g., shear web <NUM>) using conventional adhesive or resin bonding techniques.

In further embodiments, additional webs may be used. For example, the first section of a second one of the webs <NUM>(a) extends along and is bonded to a bottom outer surface <NUM>(b) of the stacked pultruded members <NUM> with the second section of this web <NUM>(b) extending across the joint interface <NUM> and bonded to the second structural component <NUM>. With this embodiment, additional "internal" webs may or may not be included. In other words, this embodiment encompasses one or more "external" webs extending across the joint interface <NUM> along the outer surfaces of the structural components <NUM>, <NUM>.

Still referring to <FIG> in general, other embodiments include one or more additional "internal" webs underlying the outermost webs <NUM>, <NUM> at the joint interface. For example, one or more additional webs (i.e., sections <NUM>(a) through <NUM>(a)) may be bonded between at least two of the pultruded members <NUM> in the first structural component <NUM> (e.g., spar cap <NUM>), with the second section (i.e., sections <NUM>(b) through <NUM>(b)) extending across the joint interface <NUM> and bonded onto or into the second structural component <NUM> (e.g., shear web <NUM>) using conventional adhesive or resin bonding techniques.

As mentioned, the improved joint interface structure <NUM> formed as described above has particular usefulness when configured between a spar cap <NUM>, <NUM> and a shear web <NUM> in a box-beam (<FIG>) or I-beam (<FIG>) spar, wherein the spar cap <NUM>, <NUM> is formed by the pultruded members <NUM> and the shear web is a unitary (<FIG>) or multi-element (<FIG>) component. It should be appreciated, however, the joint interface structure <NUM> is not limited to this use or location, and may be used between any structural components within the wind turbine <NUM> or blade16.

The webs <NUM>-<NUM> may be variously formed. In one embodiment, the webs <NUM>-<NUM> may be one or more layers of a woven or non-woven fabric materials, such as a glass matt fabric, that is sufficiently pliable so as to be woven between different ones of the pultruded members <NUM>, yet strong enough to form a rigid load-bearing joint interface <NUM> between the components. The fabric layers <NUM>-<NUM> may be bonded between the pultruded members <NUM> with an adhesive or resin during formation of the first structural member <NUM>, for example during a vacuum thermo-forming process.

In a particular embodiment, the fabric material webs <NUM>-<NUM> may be impregnated with a resin or adhesive and also serve a primary purpose of adhering or bonding the pultruded members <NUM> together to form the first structural member <NUM>. In such embodiment, the webs <NUM>-<NUM> may extend entirely throughout the width and length of the first structural member <NUM> between adjacent rows <NUM> and/or columns <NUM> of the pultruded members <NUM>.

The second structural component <NUM> may be a unitary member, such as the shear web <NUM> depicted in <FIG>, wherein the second section of each of the plurality of webs <NUM>(b) through <NUM>(b) extends alongside an outer surface <NUM> of the second structural component. The second sections of multiple webs <NUM>(b)-<NUM>(b) may overlap along the outer surface <NUM> of the second structural component <NUM>, wherein such overlapped sections are bonded to each other and to the outer surface <NUM> of the second structural component <NUM>.

In an alternate embodiment depicted for example in <FIG>, the second structural component <NUM> may be formed from a plurality of bonded-together components <NUM>, wherein the second section (b) of at least one of the plurality of webs <NUM>(b)-<NUM>(b) extends and is bonded between two or more of the bonded-together components <NUM>. In a particular embodiment, the second structural component <NUM> may also be formed from a plurality of pultruded components <NUM>, as discussed above with respect to the first structural component <NUM>.

As discussed above, the pultruded members <NUM> may be arranged in various configurations within the first structural component <NUM>. For example, as depicted in <FIG> and <FIG>, the pultruded members <NUM> may span across the entire chord-wise aspect of the first structural component <NUM> and be arranged in stacked rows <NUM>. The first section of one or more of the plurality of webs <NUM>(a)-<NUM>(a) is bonded between two adjacent stacked rows <NUM>. For example, the first section of at least one of the webs <NUM>(a)-<NUM>(a) may be bonded between each of the stacked rows <NUM> of pultruded members <NUM>, as shown in <FIG>.

As seen in <FIG>, the pultruded members <NUM> may be further arranged in adjacent columns <NUM> within the first structural member <NUM>, wherein the first section of at least one of the plurality of webs <NUM>(a)-<NUM>(b) is bonded between the pultruded members <NUM> at different height positions in adjacent ones of the columns <NUM>. In addition, the webs may weave between the columns <NUM> at a different height between adjacent columns <NUM>.

It should be appreciated that the first section of a plurality of the webs <NUM>(a)-<NUM>(a) may weave between any combination of the stacked rows <NUM> and columns <NUM> of pultruded members <NUM> within the first structural component <NUM> (or the second structural component <NUM> if formed from pultruded components <NUM> or other separate components).

Referring to <FIG>, in certain embodiments, the first sections of multiple webs <NUM>(a)-<NUM>(a) may be joined together within the first structural component <NUM> to form an interconnected network of the first sections.

Alternatively, the first section of one or more of the webs <NUM>(a)-<NUM>(a) may include a plurality of branches <NUM>, wherein each branch <NUM> extends between different pairs of the pultruded members <NUM>. It should be appreciated that the first sections <NUM>(a)-<NUM>(a) need not remain separated or distinct within the matrix of pultruded members <NUM>, but may attach or combine in any pattern between the pultruded members <NUM>.

The present invention also encompasses various methodologies for fixing a first structural component <NUM>, such as a spar cap <NUM>, <NUM>, to a second structural component <NUM>, such as a shear web <NUM>, with a plurality of webs <NUM>-<NUM>, wherein the first structural component <NUM> is formed with a plurality of stacked pultruded members <NUM>, as discussed above. In a first aspect, the method includes bonding (directly or indirectly) the first section of at least a first web <NUM>(a) along and to a top outer surface <NUM>(a) of the stacked pultruded members <NUM>, with the second section of this web <NUM>(b) extending across the joint interface <NUM> and bonded (directly or indirectly) to the second structural component <NUM> (e.g., shear web <NUM>) using conventional adhesive or resin bonding techniques. In an additional embodiment, the first section of a second one of the webs <NUM>(a) extends along and is bonded to a bottom outer surface <NUM>(b) of the stacked pultruded members <NUM> with the second section of this web <NUM>(b) extending across the joint interface <NUM> and bonded to the second structural component <NUM>.

Additional method embodiments may include bonding one or more additional webs underlying the outermost webs <NUM>, <NUM> at the joint interface <NUM>. For example, one or more additional webs (i.e., sections <NUM>(a) through <NUM>(a)) may be bonded between at least two of the pultruded members <NUM> in the first structural component <NUM> (e.g., spar cap <NUM>), with the second section (i.e., sections <NUM>(b) through <NUM>(b)) extending across the joint interface <NUM> and bonded onto or into the second structural component <NUM> (e.g., shear web <NUM>) using conventional adhesive or resin bonding techniques. These "internal" webs may be in addition to the external webs <NUM>, <NUM>.

In a particular embodiment of the method, the first structural component <NUM> is a spar cap <NUM>, <NUM>, and the second structural component <NUM> is a shear web <NUM>.

The pultruded members <NUM> may be arranged in stacked rows <NUM> and columns <NUM> in the spar cap <NUM>, <NUM>, wherein the method includes weaving the first section of at least one of the plurality of webs <NUM>(a)-<NUM>(b) between any combination of the stacked rows and columns of pultruded members <NUM>.

It should be appreciated that the various method embodiments may include any of the aspects discussed above with respect to <FIG>.

Claim 1:
A rotor blade component (<NUM>) for a wind turbine (<NUM>), the rotor blade component (<NUM>) comprising:
a first structural component (<NUM>) comprising a spar cap (<NUM>) having a plurality of stacked pultruded members (<NUM>);
a second structural component (<NUM>) comprising a shear web (<NUM>) fixed to the first structural component (<NUM>) at a joint interface (<NUM>); and
a plurality of webs (<NUM>-<NUM>), including a first web (<NUM>), each having a first section (54a-60a) and a second section (54b-60b), with a second section (56b) of the first web (<NUM>) of the plurality of webs extending across the joint interface (<NUM>) and bonded onto or into the second structural component (<NUM>), characterized in that a first section (56a) of the first web (<NUM>) of the plurality of webs is bonded between at least two of the pultruded members (<NUM>) in the first structural component (<NUM>).