Patent Description:
Wind turbine blades of fibre-reinforced polymer and in particular the aerodynamic shells of wind turbine blades are usually manufactured in moulds, where the pressure side and the suction side of the blade are manufactured separately by arranging glass fibre mats and/or other fibre-reinforcement material, such as carbon fibre, in each of the two moulds. Afterwards, one of the two halves is turned upside down and positioned on top of the other of the two halves, and the two halves are adhered together. The blade parts may be positioned on top of each other by turning and repositioning the complete half mould.

A wind turbine blade may be manufactured by infusing fibres, such as glass fibre mats and/or carbon fibre mats with a resin, such as polyester or epoxy. Infusion of the fibres may be provided by vacuum assisted resin transfer moulding (VARTM).

A wind turbine blade may comprise both glass fibre laminate and carbon fibre laminate or only glass fibres, where wind turbine blades comprising both glass and carbon fibres have some advantages over the latter, e.g. reduced weight. For example, the skin part of the wind turbine blade may be provided with glass fibre while load carrying structures, such as spar caps, may be provided with carbon fibre. During manufacture of a wind turbine blade with both glass fibre and carbon fibres, to control and ensure correct alignment of the different fibre sheets, the fibres may be laid out in the blade mould in two separate instances, e.g. first the glass fibre sheets and afterwards the carbon fibre sheets and infused between each instance. Thus, the infusion process is performed twice, one infusion for the glass fibres and a second infusion for the carbon fibres. The infusion process is time consuming thus, in an effort to reduce manufacturing time, it would be advantageous to reduce infusion time.

Furthermore, some regions of the wind turbine blade need to be relatively strong. In these regions of the blade a plurality of fabric sheets is stacked on top of each other. Stacking these fabric sheets is time consuming and require precision, thus, reduction of the time spent on laying up the fibres in the blade mould may also be desirable. It is known to form pre-forms comprising a plurality of fabric sheets offline, i.e. outside the blade mould. The plurality of fabric sheets may comprise carbon fibres or glass fibres, which are cut and stacked to form a desired pre-form shape. The sheets may comprise a tackifier binding the sheets together during a consolidation process. The pre-form may subsequently be placed in a desired location in the blade mould in one single operation, thereby reducing the time spent with the blade mould on stacking sheets of fabric in the blade mould. However, a disadvantage with making pre-formed sections of laminates is that they require a substantial extra amount of factory space.

<CIT> describes a large-plate production device for creating large-area composite material plates for use as body panels comprising a table surface for arranging at least one layer of a composite material plate and a means for fixing one or more layers of the composite materials on the table surface, wherein the table surface is movable so that the layer fixed on the table surface, preferably a composite material having several layers, can be moved from a position for equipping and/or fixing to a position for preferably curing. <CIT> discloses a moulding apparatus for forming a first shell half and a second shell half of a wind turbine blade. However, neither <CIT> nor <CIT> solves the problems described above.

It is an object of the present disclosure to provide a mould tool and a method for manufacturing a plurality of pre-form laminates which overcomes at least some of the disadvantages of the prior art.

In particular, it is an object of the present invention to provide a mould tool and a method for manufacturing a plurality of pre-form laminates which reduces the infusion time during manufacturing of wind turbine blades, e.g. by facilitating a single infusion process for infusing both glass fibre parts and carbon fibre parts in the wind turbine blade mould (may be a half-mould) simultaneously.

Thus, the present invention relates to manufacture of a plurality of pre-form laminates for a laminate of a wind turbine blade. The pre-form laminates may comprise sheets of fibres, such as carbon fibres, which are adhered together by an adhesive, and which may be positioned together with other sheets of fibres, such as glass fibres, in the wind turbine blade mould. This may facilitate simultaneous resin infusion of both types of fibres, e.g. glass fibre and carbon fibre. The adhesive of the pre-form laminates may be configured to be dissolved by the resin as it is infused, such that the adhesive is replaced by resin during the infusion process.

The present invention relates to a mould tool according to claim <NUM> for manufacturing a plurality of pre-form laminates for a laminate of a wind turbine blade shell, e.g. including a first pre-form laminate and a second pre-form laminate, for a laminate of a wind turbine blade.

The mould tool comprises a frame, a first mould surface configured for receiving a first fabric, a second mould surface configured for receiving a second fabric, and a heating arrangement configured to heat the first mould surface and the second mould surface.

The mould tool is configured to turn between a first configuration and a second configuration, wherein in the first configuration the first mould surface is facing substantially upwards, and in the second configuration the second mould surface is facing substantially upwards. In the first configuration the second mould surface may be facing substantially downwards. In the second configuration the first mould surface may be facing substantially downwards.

The mould tool may be configured to receive the first fabric on the first mould surface while being in the first configuration.

The mould tool is configured to while the first fabric is being consolidated including heating the first mould surface, turn the mould tool to be in the second configuration and receive the second fabric on the second mould surface.

The mould tool may comprise a third mould surface. The mould tool may be configured to turn between the first configuration, the second configuration and a third configuration. In the third configuration the third mould surface may be facing substantially upwards. The third mould surface may be configured for receiving a third fabric.

The present invention relates also to a method according to claim <NUM> for manufacturing a plurality of pre-form laminates for a laminate of a wind turbine blade with a mould tool, such as the mould tool disclosed above.

The method comprises positioning the mould tool in the first configuration, providing a first fabric, laying up the first fabric on the first mould surface, restraining the first fabric on the first mould surface, and consolidating the first fabric including heating the first mould surface to form a first pre-form laminate of the plurality of pre-form laminates.

The method comprises, while consolidating the first fabric, turning the mould tool to the second configuration, providing a second fabric, laying up the second fabric on the second mould surface, restraining the second fabric on the second mould surface, and consolidating the second fabric including heating the second mould surface to form a second pre-form laminate of the plurality of pre-form laminates.

It is an advantage of the present disclosure that a plurality of pre-form laminates may be provided with reduced space requirement, e.g. several pre-form laminates may be manufactured at a ground area not much bigger than a single pre-form laminate.

It is an advantage of the present disclosure that a plurality of pre-form laminates may be provided, such that a single infusion may be facilitated during manufacturing of a wind turbine blade, thereby reducing manufacturing time.

It is a further advantage of the present disclosure that it may reduce the infusion time of the wind turbine blade by facilitating the infusion process in the blade mould to be performed in one step; infusing the different fibres, e.g. glass fibres and carbon fibres, at the same time, once the one fibre type, e.g. carbon fibres, have been placed in a controlled way as the pre-form laminate to reduce or even avoid the risk of defects.

The mould tool comprises a plurality of mould surfaces including the first mould surface and the second mould surface. The plurality of mould surfaces may include the third mould surface. The plurality of mould surfaces may include more mould surfaces, such as a fourth mould surface and a fifth mould surface.

The mould surfaces are configured for receiving fabrics, e.g. the first mould surface is configured to receive a first fabric, the second mould surface is configured to receive a second fabric. The third mould surface may be configured to receive a third fabric. The first mould surface may be configured to receive a first secondary fabric. The second mould surface may be configured to receive a second secondary fabric. The third mould surface may be configured to receive a third secondary fabric.

Consolidation of the fabrics, e.g. including heating of the fabrics, forms the pre-form laminates. For example, consolidation of the first fabric forms the first pre-form laminate and consolidation of the second fabric forms the second pre-form laminate. Consolidation of the third fabric forms the third pre-form laminate. Consolidation of the first secondary fabric forms the first secondary pre-form laminate. Consolidation of the second secondary fabric forms the second secondary pre-form laminate. Consolidation of the third secondary fabric forms the third secondary pre-form laminate.

The pre-form laminates are not necessarily rigid after being consolidated. For example, the pre-form laminates may be flexible after the consolidation process. For example, the pre-form laminates may be able to attain some degree of curvature after consolidation, e.g. when being positioned in the wind turbine blade mould.

The pre-form laminates may constitute a part of the main laminate of the wind turbine blade. The pre-form laminates may constitute a part of the spar cap of a wind turbine blade. A fabric, such as the first fabric and/or the second fabric and/or the third fabric and/or the first secondary fabric and/or the second secondary fabric and/or the third secondary fabric, may comprise carbon fibres.

A fabric may comprise a plurality of sheets of fabric and/or a plurality of sets of a plurality of sheets of fabric. A fabric may comprise carbon fibres. A fabric may be prefabricated with a tackifier. A fabric may be a pre-preg fabric. Alternatively, the fabric may be dry fabric.

The first fabric may comprise a plurality of sheets of fabric and/or a plurality of sets of a plurality of sheets of fabric. The first fabric may comprise carbon fibres. The first fabric may be prefabricated with a tackifier. The first fabric may be a pre-preg fabric. Alternatively, the first fabric may be dry fabric.

The second fabric may comprise a plurality of sheets of fabric and/or a plurality of sets of a plurality of sheets of fabric. The second fabric may comprise carbon fibres. The second fabric may be prefabricated with a tackifier. The second fabric may be a pre-preg fabric. Alternatively, the second fabric may be dry fabric.

The first secondary fabric may comprise a plurality of sheets of fabric and/or a plurality of sets of a plurality of sheets of fabric. The first secondary fabric may comprise carbon fibres. The first secondary fabric may be prefabricated with a tackifier. The first secondary fabric may be a pre-preg fabric. Alternatively, the first secondary fabric may be dry fabric.

The third fabric may comprise a plurality of sheets of fabric and/or a plurality of sets of a plurality of sheets of fabric. The third fabric may comprise carbon fibres. The third fabric may be prefabricated with a tackifier. The third fabric may be a pre-preg fabric. Alternatively, the third fabric may be dry fabric.

The second secondary fabric may comprise a plurality of sheets of fabric and/or a plurality of sets of a plurality of sheets of fabric. The second secondary fabric may comprise carbon fibres. The second secondary fabric may be prefabricated with a tackifier. The second secondary fabric may be a pre-preg fabric. Alternatively, the second secondary fabric may be dry fabric.

The third secondary fabric may comprise a plurality of sheets of fabric and/or a plurality of sets of a plurality of sheets of fabric. The third secondary fabric may comprise carbon fibres. The third secondary fabric may be prefabricated with a tackifier. The third secondary fabric may be a pre-preg fabric. Alternatively, the third secondary fabric may be dry fabric.

A mould surface may comprise a centre point. For example, the first mould surface may comprise a first centre point. The second mould surface may comprise a second centre point. The third mould surface may comprise a third centre point.

A normal to the first mould surface at the first centre point may point in a first primary direction in the first configuration. A normal to the second mould surface at the second centre point may point in a second primary direction in the first configuration. A normal to the third mould surface at the third centre point may point in a third primary direction in the first configuration.

The first primary direction and the second primary direction may be angularly spaced by more than <NUM> degrees, such as by <NUM> degrees and/or <NUM> degrees. The first primary direction and the third primary direction may be angularly spaced by between <NUM> and <NUM> degrees, such as <NUM> degrees. The second primary direction and the third primary direction may be angularly spaced between <NUM> and <NUM> degrees, such as <NUM> degrees.

The normal to the first mould surface at the first centre point may point in a first secondary direction in the second configuration. The normal to the second mould surface at the second centre point may point in a second secondary direction in the second configuration. The normal to the third mould surface at the third centre point may point in a third secondary direction in the second configuration.

The first secondary direction and the second secondary direction may be angularly spaced by more than <NUM> degrees, such as by <NUM> degrees and/or <NUM> degrees. The first secondary direction and the third secondary direction may be angularly spaced by between <NUM> and <NUM> degrees, such as <NUM> degrees. The second secondary direction and the third secondary direction may be angularly spaced between <NUM> and <NUM> degrees, such as <NUM> degrees.

The normal to the first mould surface at the first centre point may point in a first tertiary direction in the third configuration. The normal to the second mould surface at the second centre point may point in a second tertiary direction in the third configuration. The normal to the third mould surface at the third centre point may point in a third tertiary direction in the third configuration.

The first tertiary direction and the second tertiary direction may be angularly spaced by more than <NUM> degrees, such as by <NUM> degrees and/or <NUM> degrees. The first tertiary direction and the third tertiary direction may be angularly spaced by between <NUM> and <NUM> degrees, such as <NUM> degrees. The second tertiary direction and the third tertiary direction may be angularly spaced between <NUM> and <NUM> degrees, such as <NUM> degrees.

The mould tool may be turned about a rotation axis. The rotation axis may be a longitudinal axis of the mould tool and/or the rotation axis may be parallel to the longitudinal axis of the mould tool. The mould tool may comprise a turning device configured for turning the mould between the configurations, such as between the first configuration and the second configuration and/or between the first configuration and the third configuration and/or between the second configuration and the third configuration. The turning device may rotate about the rotation axis, such as the longitudinal axis of the mould tool.

The first primary direction may be upwards, such as above horizontal. The first primary direction may be substantially vertical, such as vertically upwards. The first primary direction may be in a plane perpendicular to the rotation axis and/or perpendicular to the longitudinal axis of the mould tool.

The second primary direction may be downwards, such as below horizontal. The second primary direction may be substantially vertical, such as vertically downwards. The second primary direction may be in the plane perpendicular to the rotation axis and/or perpendicular to the longitudinal axis of the mould tool.

The first primary direction may be the opposite direction of the second primary direction.

The third primary direction may be downwards, such as below horizontal. Alternatively, the third primary direction may be substantially horizontal. The third primary direction may be in the plane perpendicular to the rotation axis and/or perpendicular to the longitudinal axis of the mould tool.

The first secondary direction may be downwards, such as below horizontal. The first secondary direction may be substantially vertical, such as vertically downwards. The first secondary direction may be in the plane perpendicular to the rotation axis and/or perpendicular to the longitudinal axis of the mould tool.

The second secondary direction may be upwards, such as above horizontal. The second secondary direction may be substantially vertical, such as vertically upwards. The second secondary direction may be in the plane perpendicular to the rotation axis and/or perpendicular to the longitudinal axis of the mould tool.

The first secondary direction may be the opposite direction of the second secondary direction.

The third secondary direction may be downwards, such as below horizontal. Alternatively, the third secondary direction may be substantially horizontal. The third secondary direction may be in the plane perpendicular to the rotation axis and/or perpendicular to the longitudinal axis of the mould tool.

The first tertiary direction may be downwards, such as below horizontal. Alternatively, the first tertiary direction may be substantially horizontal. The first tertiary direction may be in the plane perpendicular to the rotation axis and/or perpendicular to the longitudinal axis of the mould tool.

The second tertiary direction may be downwards, such as below horizontal. Alternatively, the second tertiary direction may be substantially horizontal. The second tertiary direction may be in the plane perpendicular to the rotation axis and/or perpendicular to the longitudinal axis of the mould tool.

The first tertiary direction may be the opposite direction of the second tertiary direction.

The third tertiary direction may be upwards, such as above horizontal. The third tertiary direction may be substantially vertical, such as vertically upwards. The third tertiary direction may be in the plane perpendicular to the rotation axis and/or perpendicular to the longitudinal axis of the mould tool.

According to the claims the first mould surface and/or the second mould surface are curved , e.g. to account for the geometry of the surface of the wind turbine blade shell. The third mould surface may be curved. A mould surface, such as the first mould surface and/or the second mould surface and/or the third mould surface may be planar. Some of the mould surfaces may be planar while others of the mould surfaces may be curved. At least one of the mould surfaces is curved. One or more of the mould surfaces may be planar.

The curvature of a mould surface, such as the curvature of the first mould surface and/or the second mould surface and/or the third mould surface, may be concave, e.g. to account for the geometry of the upwind or the downwind surface of the wind turbine blade shell. The curvature of a mould surface, such as the curvature of the first mould surface and/or the second mould surface and/or the third mould surface, may be convex, e.g. to account for the geometry of the downwind or the upwind surface of the wind turbine blade shell. Some of the mould surfaces may be concave others of the mould surfaces may be convex and others of the mould surfaces may be planar. For example, the curvature of the first mould surface may be convex and the curvature of the second mould surface may be concave. The first mould surface and the second mould surface may have the same curvature. The first mould surface and the second mould surface may have the opposite curvature. The first mould surface and the third mould surface may have the same curvature. The first mould surface and the third mould surface may have the opposite curvature. The third mould surface and the second mould surface may have the same curvature. The third mould surface and the second mould surface may have the opposite curvature.

One or more sealing members may be provided. For example, the mould tool may comprise one or more sealing members. For example, the mould tool may comprise a first sealing member and/or a second sealing member and/or a third sealing member. The first sealing member and/or the second sealing member and/or the third sealing member may comprise a lid and optionally a clamp for locking the lid in a closed position. The lid may be hinged to a side of a respective mould surface.

The first sealing member and/or the second sealing member and/or the third sealing member may comprise a vacuum bag. The vacuum bag may be applied to the mould surface, such as the first mould surface and/or the second mould surface and/or the third mould surface, respectively. The vacuum bag may be fastened, e.g. by double sided tape, to the edges of the respective mould surface, such as the first mould surface and/or the second mould surface and/or the third mould surface.

Restraining a fabric may comprise closing the sealing member over the respective mould surface. Restraining the first fabric may comprise closing the first sealing member over the first mould surface. Restraining the second fabric may comprise closing the second sealing member over the first mould surface. Restraining the third fabric may comprise closing the third sealing member over the third mould surface. Restraining the first secondary fabric may comprise closing the first sealing member over the first mould surface. Restraining the second secondary fabric may comprise closing the second sealing member over the second mould surface. The sealing member(s) secures the pre-form laminate(s) from falling out when the mould tool is turned.

Consolidating a fabric may comprise applying vacuum between the respective sealing member and mould surface. Consolidating the first fabric may comprise applying vacuum between the first sealing member and the first mould surface. Consolidating the second fabric may comprise applying vacuum between the second sealing member and the second mould surface. Consolidating the third fabric may comprise applying vacuum between the third sealing member and the third mould surface. Consolidating the first secondary fabric may comprise applying vacuum between the first sealing member and the first mould surface. Consolidating the second secondary fabric may comprise applying vacuum between the second sealing member and the second mould surface. Consolidating the third secondary fabric may comprise applying vacuum between the third sealing member and the third mould surface.

The method may comprise, e.g. while consolidating the second fabric and/or the third fabric, turning the mould tool to the first configuration and demoulding the first pre-form laminate.

The method may comprise, e.g. after demoulding the first pre-form laminate, providing a first secondary fabric and laying up the first secondary fabric on the first mould surface. The method may further comprise restraining the first secondary fabric on the first mould surface, e.g. with the first sealing member, and consolidating the first secondary fabric including heating the first mould surface to form a first secondary pre-form laminate of the plurality of pre-form laminates.

The method may comprise, e.g. while consolidating the second fabric and/or the first fabric, turning the mould tool to the third configuration, providing a third fabric and laying up the third fabric on the third mould surface. The method may further comprise restraining the third fabric on the third mould surface, e.g. with the third sealing member, and consolidating the third fabric including heating the third mould surface to form a third pre-form laminate of the plurality of pre-form laminates.

The method may comprise turning the mould tool to the second configuration and demoulding the second pre-form laminate.

Laying up a fabric on a mould surface may comprise applying a tackifier to the fabric. For example, laying up the first fabric on the first mould surface may comprise applying a tackifier to the first fabric. Laying up the second fabric on the second mould surface may comprise applying a tackifier to the second fabric. Laying up the first secondary fabric on the first mould surface may comprise applying a tackifier to the first secondary fabric. Laying up the second secondary fabric on the second mould surface may comprise applying a tackifier to the second secondary fabric. Laying up the third fabric on the third mould surface may comprise applying a tackifier to the third fabric. Laying up the third secondary fabric on the third mould surface may comprise applying a tackifier to the third secondary fabric.

Providing a fabric may comprise providing the fabric prefabricated with a tackifier. For example, providing the first fabric may comprise providing a first fabric prefabricated with a tackifier. Providing the second fabric may comprise providing a second fabric prefabricated with a tackifier. Providing the third fabric may comprise providing a third fabric prefabricated with a tackifier. Providing the first secondary fabric may comprise providing a first secondary fabric prefabricated with a tackifier. Providing the second secondary fabric may comprise providing a second secondary fabric prefabricated with a tackifier. Providing the third secondary fabric may comprise providing a third secondary fabric prefabricated with a tackifier.

It is envisaged that any embodiments or elements as described in connection with any one aspect may be used with any other aspects or embodiments, mutatis mutandis.

Embodiments of the invention will be described in more detail in the following with regard to the accompanying figures. Like elements may, thus, not be described in detail with respect to the description of each figure. The figures show one way of implementing the present invention and are not to be construed as being limiting to other possible embodiments falling within the scope of the attached claim set.

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

<FIG> illustrates a conventional modern upwind wind turbine <NUM> according to the so-called "Danish concept" with a tower <NUM>, a nacelle <NUM> and a rotor with a substantially horizontal rotor shaft. The rotor includes a hub <NUM> and three blades <NUM> extending radially from the hub <NUM>, each having a blade root <NUM> nearest the hub and a blade tip <NUM> furthest from the hub <NUM>.

The wind turbine blade <NUM> has the shape of a conventional wind turbine blade with a root end and a tip end and comprises a root region <NUM> closest to the hub, a profiled or an airfoil region <NUM> furthest away from the hub and a transition region <NUM> between the root region <NUM> and the airfoil region <NUM>.

The wind turbine blade <NUM> comprises a blade shell comprising two blade shell parts, a first blade shell part <NUM> and a second blade shell part <NUM>, typically made of fibre-reinforced polymer. The first blade shell part <NUM> is typically a pressure side or upwind blade shell part. The second blade shell part <NUM> is typically a suction side or downwind blade shell part. The first blade shell part <NUM> and the second blade shell part <NUM> are fastened together with adhesive, such as glue, along bond lines or glue joints <NUM> extending along the trailing edge <NUM> and the leading edge <NUM> of the blade <NUM>. Typically, the root ends of the blade shell parts <NUM>, <NUM> has a semi-circular or semi-oval outer cross-sectional shape.

<FIG> is a schematic diagram illustrating a cross sectional view of an exemplary wind turbine blade <NUM>, e.g. a cross sectional view of the airfoil region of the wind turbine blade <NUM>. The wind turbine blade <NUM> comprises a leading edge <NUM>, a trailing edge <NUM>, a pressure side <NUM>, a suction side <NUM> a first spar cap <NUM>, and a second spar cap <NUM>. The wind turbine blade <NUM> comprises a chord line <NUM> between the leading edge <NUM> and the trailing edge <NUM>. The wind turbine blade <NUM> comprises shear webs <NUM>, such as a leading edge shear web and a trailing edge shear web. The shear webs <NUM> could alternatively be a spar box with spar sides, such as a trailing edge spar side and a leading edge spar side. The spar caps <NUM>, <NUM> may comprise carbon fibres while the rest of the shell parts <NUM>, <NUM> may comprise glass fibres. Employing both glass fibres and carbon fibres may provide challenges in order to maintain orientation of fibre-layers when different fibre-types react differently while infusing and curing with resin and also challenging maintaining fibre straightness, especially in carbon fibres, during a single infusion manufacturing process. One way of solving this issue have been to utilize a dual infusion process involving infusing and curing of one fibre type, and afterwards laying up the second fibre type which is then infused and cured. To reduce total infusion and curing time required for manufacturing of a wind turbine blade comprising both glass fibres and carbon fibres, the spar caps <NUM>, <NUM>, e.g. being made of carbon fibres, may be provided as pre-form laminates, where an adhesive is applied to the carbon fibre layers in order to maintain their position and orientation, ready to be put in the wind turbine blade mould, allowing a single infusion to infuse both the glass fibre layers and the carbon fibre layers and minimizing the risk of introducing fibre misalignments, especially in carbon fibres, during the manufacturing process.

<FIG> are schematic diagrams illustrating exemplary mould tools for manufacturing pre-form laminates, e.g. spar cap pre-form laminates. Alternatively, the pre-form laminates may be part of other parts of the wind turbine blade, such as the skin. The mould tools <NUM>', <NUM>', <NUM>" are examples of different exemplary mould tools. The mould tool <NUM> in <FIG> comprises a rack <NUM>, a first mould surface <NUM> and a second mould surface <NUM>. The mould tool <NUM>' in <FIG> comprises a rack <NUM>', a first mould surface <NUM>' and a second mould surface <NUM>'. The mould tool <NUM>" in <FIG> comprises a rack <NUM>", a first mould surface <NUM>" and a second mould surface <NUM>". The rack <NUM>, <NUM>', <NUM>" may comprise scaffolding such as the racks <NUM>, <NUM>' as exemplified in <FIG>. Alternatively, the rack <NUM>, <NUM>', <NUM>" may comprise a system of beams such as the rack <NUM>" as exemplified in <FIG>. The first mould surface <NUM>, <NUM>', <NUM>" and/or the second mould surface <NUM>, <NUM>', <NUM>" is curved. One or more of the first mould surfaces <NUM>, <NUM>', <NUM>" and the second mould surfaces <NUM>, <NUM>', <NUM>" may be planar. The first mould surface <NUM>, <NUM>', <NUM>" may be arranged opposite the second mould surface <NUM>, <NUM>', <NUM>". Alternatively, mould surfaces may abut other mould surfaces, e.g. mould surfaces may be perpendicular to each other. The first mould surface <NUM>, <NUM>', <NUM>" and the second mould surface <NUM>, <NUM>', <NUM>" may be concave or convex. The first mould surface <NUM>, <NUM>', <NUM>" and the second mould surface <NUM>, <NUM>', <NUM>" may have the same curvature or have different curvatures. As illustrated in <FIG>, the first mould surface <NUM>' may be concave while the second mould surface <NUM>' may be convex. The mould tools <NUM>, <NUM>', <NUM>" extends along a longitudinal axis L.

The mould tools <NUM>, <NUM>', <NUM>" may comprise a heating arrangement (not shown) configured for heating the mould surfaces <NUM>, <NUM>', <NUM>", <NUM>, <NUM>', <NUM>". The heating arrangement may be configured to heat the mould surfaces <NUM>, <NUM>', <NUM>", <NUM>, <NUM>', <NUM>" such that a tackifier or binder, such as glue, e.g. as provided with the fabric, are heated to consolidate the fabric and thus create a pre-form laminate. The heating arrangement may comprise a first heating element for heating the first mould surface <NUM>, <NUM>', <NUM>" and a second heating element for heating the second mould surface <NUM>, <NUM>', <NUM>".

For simplicity, the following figures may illustrate features with respect to only one or some of the mould tools <NUM>, <NUM>', <NUM>" as illustrated in <FIG>. However, any other mould tool, such as any other of the mould tools <NUM>, <NUM>', <NUM>" of <FIG>, may comprise the features described in the following.

<FIG> are schematic diagrams illustrating exemplary mould tools <NUM>, <NUM>', such as the mould tools <NUM>, <NUM>' of the previous figures. The mould tools <NUM>, <NUM>' comprise a first mould surface <NUM>, <NUM>' and a second mould surface <NUM>, <NUM>'. The first mould surface <NUM>, <NUM>' is configured for receiving a first fabric to create a first pre-form laminate <NUM>, <NUM>' and the second mould surface <NUM>, <NUM>' is configured for receiving a second fabric to create a second pre-form laminate <NUM>, <NUM>'.

<FIG> are schematic diagrams illustrating exemplary mould tools <NUM>, <NUM>', such as the mould tools <NUM>, <NUM>' of the previous figures. The mould tools <NUM>, <NUM>' comprise a first mould surface <NUM>, <NUM>' and a second mould surface <NUM>, <NUM>'. The mould tools <NUM>, <NUM>' comprise a turning device <NUM>, <NUM>' configured for turning the mould tools <NUM>, <NUM>' from a first configuration to a second configuration about a rotation axis R, such as the longitudinal axis L of the mould tools <NUM>, <NUM>'. The mould tools <NUM>, <NUM>' comprise a first sealing member <NUM>, <NUM>' and a second sealing member <NUM>, <NUM>'. As illustrated, the sealing members <NUM>, <NUM>', <NUM>, <NUM>' may be formed by a lid, e.g. a vacuum tight lid, e.g. a vacuum may be applied between the lid in a closed position and the respective mould surface. The lid may be secured in a closed position with a clamp and/or a plurality of clamps. The first sealing member <NUM>, <NUM>' is configured to restrain fabric on the first mould surface <NUM>, <NUM>', e.g. with vacuum applied between the first sealing member <NUM>, <NUM>' and the first mould surface <NUM>, <NUM>'. For example, the fabric may be restrained on the first mould surface <NUM>, <NUM>', when turning the mould tool <NUM>, <NUM>', such as when the first mould surface <NUM>, <NUM>' is facing downwards. The second sealing member <NUM>, <NUM>' is configured to restrain fabric on the second mould surface <NUM>, <NUM>', e.g. with vacuum applied between the second sealing member <NUM>, <NUM>' and the second mould surface <NUM>, <NUM>'. For example, the fabric may be restrained on the second mould surface <NUM>, <NUM>' when the second mould surface <NUM>, <NUM>' is facing downwards. Alternatively, sealing members may be provided by a vacuum bag applied to the mould surfaces and being fastened to the edges of the mould surfaces, and by applying a vacuum between the vacuum bag and the respective mould surface. The sealing members <NUM>, <NUM>', <NUM>, <NUM>' secures the pre-form laminates from falling out when the mould tools <NUM>, <NUM>' are turned. The sealing members <NUM>, <NUM>', <NUM>, <NUM>' also allow applying a vacuum for the consolidation process of the pre-form laminate.

<FIG> are schematic diagrams illustrating an exemplary method of manufacturing a pre-form laminate with a mould tool. For simplicity the method is illustrated with a mould tool <NUM>, such as the mould tool <NUM> of <FIG>. However, the method is applicable to any exemplary mould tool.

The method comprises positioning the mould tool <NUM> in a first configuration, where the first mould surface <NUM> is facing substantially upwards (<FIG>). The method comprises providing a first fabric <NUM> (<FIG>). The first fabric <NUM> may comprise a plurality of sheets of fabric and/or a plurality of sets of a plurality of sheets of fabric. The first fabric <NUM> may comprise carbon fibre. The first fabric <NUM> may be prefabricated with a tackifier. Alternatively, the first fabric <NUM> may be dry fabric. The method comprises laying up the first fabric <NUM> on the first mould surface <NUM> and restraining the first fabric <NUM> on the first mould surface <NUM>, e.g. with the first sealing member <NUM>, i.e. by closing the lid (<FIG>). Furthermore, vacuum may be applied between the first sealing member <NUM> and the first mould surface <NUM>. As also described above, the first sealing member may alternatively be a vacuum bag, which is applied to the first mould surface <NUM> and attached to the edges of the first mould surface <NUM>.

The mould tool <NUM> comprises a heating arrangement (not shown) configured for heating the surface of the mould surfaces <NUM>, <NUM>. The heating arrangement heats the mould surfaces such that a tackifier or binder, such as glue, in the fabrics are heated to consolidate the fabric and thus create a pre-form laminate. The fabrics may be fabricated without any tackifiers, such as dry fabrics. In the case the fabrics are dry fabrics, a tackifier may be applied to the fabric, e.g. between sheets of the fabric, before the fabric is restrained to the mould surface. Alternatively, the fabrics may be prefabricated with tackifiers.

The method comprises consolidating the first fabric <NUM>. Consolidating the first fabric <NUM> may comprise applying vacuum between the first sealing member <NUM> and the first mould surface <NUM> and heating the first fabric <NUM>, e.g. by heating the first mould surface <NUM>.

While consolidating the first fabric <NUM>, which usually takes a few hours, and the first fabric <NUM> being restrained on the first mould surface <NUM>, the mould tool <NUM> is turned from the first configuration (<FIG>) to a second configuration (<FIG>), e.g. with a turning device <NUM>. In the first configuration (<FIG>) the first mould surface <NUM> is facing substantially upwards, e.g. such that a normal n1 at a first centre point <NUM> of the first mould surface <NUM> is pointing upwards, such as vertically upwards. In the first configuration (<FIG>) the second mould surface <NUM> is facing substantially downwards, e.g. such that a normal n2 at a second centre point <NUM> of the second mould surface <NUM> is pointing downwards, such as vertically downwards. In the second configuration (<FIG>) the first mould surface <NUM> is facing substantially downwards, e.g. such that the normal n1 at the first centre point <NUM> of the first mould surface <NUM> is pointing downwards, such as vertically downwards In the second configuration the second mould surface <NUM> is facing substantially upwards, such that the normal n2 at the second centre point <NUM> of the second mould surface <NUM> is pointing upwards, such as vertically upwards.

The method comprises providing a second fabric <NUM> (<FIG>). The second fabric <NUM> may comprise a plurality of sheets of fabric and/or a plurality of sets of a plurality of sheets of fabric. The second fabric <NUM> may comprise carbon fibres. The second fabric <NUM> may be prefabricated with a tackifier.

Alternatively, the second fabric <NUM> may be dry fabric. The method comprises laying up the second fabric <NUM> on the second mould surface <NUM> and restraining the second fabric <NUM> on the second mould surface <NUM>, e.g. with the second sealing member <NUM>, i.e. by closing the lid (<FIG>). Furthermore, vacuum may be applied between the second sealing member <NUM> and the second mould surface <NUM>. As also described above, the second sealing member may alternatively be a vacuum bag, which is applied to the second mould surface <NUM> and attached to the edges of the second mould surface <NUM>.

The method comprises consolidating the second fabric <NUM>. Consolidating the second fabric <NUM> may comprise applying vacuum between the second sealing member <NUM> and the second mould surface <NUM> and heating the second fabric <NUM>, e.g. by heating the second mould surface <NUM>.

While consolidating the second fabric <NUM> and the second fabric <NUM> being restrained on the second mould surface <NUM>, the mould tool <NUM> may be turned from the second configuration (<FIG>) to the first configuration (<FIG>), e.g. with the turning device <NUM>. In the second configuration (<FIG>) the second mould surface <NUM> is facing substantially upwards, such that the normal n2 at the second centre point <NUM> of the second mould surface <NUM> is pointing upwards, such as vertically upwards. In the second configuration (<FIG>) the first mould surface <NUM> is facing substantially downwards, such that the normal n1 at the first centre point <NUM> of the first mould surface <NUM> is pointing downwards, such as vertically downwards. In the first configuration (<FIG>) the second mould surface <NUM> is facing substantially downwards, such that the normal n2 at the second centre point <NUM> of the second mould surface <NUM> is pointing downwards, such as vertically downwards In the first configuration (<FIG>) the first mould surface <NUM> is facing substantially upwards, such that the normal n1 at the first centre point <NUM> of the first mould surface <NUM> is pointing upwards, such as vertically upwards.

The first fabric <NUM> forming a first pre-form laminate <NUM> is allowed to cool, e.g. before turning the mould tool from the second configuration to the first configuration (<FIG>), and the first sealing member <NUM> is removed, such as opened, (<FIG>) and the first pre-form laminate <NUM> is demoulded (<FIG>).

The method may start over by providing a first secondary fabric <NUM> and laying up the first secondary fabric <NUM> on the first mould surface <NUM> (<FIG>). The first secondary fabric <NUM> may comprise a plurality of sheets of fabric and/or a plurality of sets of a plurality of sheets of fabric. The first secondary fabric <NUM> may comprise carbon fibres. The first secondary fabric <NUM> may be prefabricated with a tackifier. Alternatively, the first secondary fabric <NUM> may be dry fabric. The first secondary fabric <NUM> is restrained by closing the first sealing member <NUM> (<FIG>). The mould tool <NUM> is turned from the first configuration (<FIG>) to the second configuration (7n), e.g. with the turning device <NUM>. The second fabric <NUM> forming a second pre-form laminate <NUM> is allowed to cool and the second sealing member <NUM> is removed, such as opened, (<FIG>) and the second pre-form laminate <NUM> is demoulded (<FIG>).

The method may be continued with providing a new fabric for as long as pre-form laminates are needed.

Although not specifically illustrated, the mould tool may comprise a third mould surface (e.g. the mould tool may have a triangular cross section), and the method may comprise, while consolidating the second fabric <NUM> and/or the first fabric <NUM>, turning the mould tool to a third configuration, wherein the third mould surface is facing substantially upwards. The method may comprise providing a third fabric and laying up the third fabric on the third mould surface. The method may comprise restraining the third fabric with a third sealing member on the third mould surface. The method may comprise consolidating the third fabric, e.g. by applying vacuum between the third sealing member and the third mould surface and heating the third mould surface.

It will be realised that a mould tool according to the present disclosure may comprise any other reasonable plurality of mould surfaces, e.g. four mould surfaces, five mould surfaces, etc..

<FIG> are block diagrams of exemplary methods <NUM>, <NUM>' for manufacturing a plurality of pre-form laminates for a laminate of a wind turbine blade with a mould tool, such as a mould tool <NUM>, <NUM>', <NUM>" as described with respect to the previous figures.

In <FIG> the method <NUM> comprises positioning <NUM> the mould tool in a first configuration, wherein a first mould surface of the mould tool is facing substantially upwards. In the first configuration a second mould surface of the mould tool may be facing substantially downwards. The method <NUM> comprises providing <NUM> a first fabric and laying up <NUM> the first fabric on the first mould surface. Providing <NUM> the first fabric may comprise providing <NUM> a first fabric prefabricated with a tackifier. Laying up <NUM> the first fabric may comprise applying <NUM> a tackifier to the first fabric. The method <NUM> comprises restraining <NUM> the first fabric on the first mould surface. The method <NUM> comprises consolidating <NUM> the first fabric including heating the first mould surface to form a first pre-form laminate of the plurality of pre-form laminate. Consolidating <NUM> the first fabric may further include applying a vacuum between a first sealing member and the first mould surface.

The method <NUM> comprises while consolidating the first fabric turning <NUM> the mould tool to a second configuration wherein the second mould surface is facing substantially upwards. In the second configuration the first mould surface may be facing substantially downwards.

The method <NUM> comprises providing <NUM> a second fabric and laying up <NUM> the second fabric on the second mould surface. Providing <NUM> the second fabric may comprise providing <NUM> a second fabric prefabricated with a tackifier. Laying up <NUM> the second fabric may comprise applying <NUM> a tackifier to the second fabric. The method <NUM> comprises restraining <NUM> the second fabric on the second mould surface. The method <NUM> comprises consolidating <NUM> the second fabric including heating the second mould surface to form a second pre-form laminate of the plurality of pre-form laminates. Consolidating <NUM> the second fabric may further include applying a vacuum between a second sealing member and the second mould surface.

The method <NUM> may comprise turning <NUM> the mould tool to the first configuration and demoulding <NUM> the first pre-form laminate, e.g. while consolidating <NUM> the second fabric.

The method <NUM> may comprise turning <NUM> the mould tool to the second configuration and demoulding <NUM> the second pre-form laminate.

<FIG> illustrates a method <NUM>' similar to the method <NUM>, but with a mould tool comprising three (or more) mould surfaces. The method <NUM>' comprises positioning <NUM> the mould tool in a first configuration, wherein a first mould surface of the mould tool is facing substantially upwards. In the first configuration a second mould surface and/or a third mould surface of the mould tool may be facing substantially downwards. The method <NUM>' comprises providing <NUM> a first fabric and laying up <NUM> the first fabric on the first mould surface. Providing <NUM> the first fabric may comprise providing <NUM> a first fabric prefabricated with a tackifier. Laying up <NUM> the first fabric may comprise applying <NUM> a tackifier to the first fabric. The method <NUM>' comprises restraining <NUM> the first fabric on the first mould surface. The method <NUM>' comprises consolidating <NUM> the first fabric including heating the first mould surface to form a first pre-form laminate of the plurality of pre-form laminate. Consolidating <NUM> the first fabric may further include applying a vacuum between a first sealing member and the first mould surface.

The method <NUM>' comprises while consolidating <NUM> the first fabric turning <NUM> the mould tool to a second configuration wherein the second mould surface is facing substantially upwards. In the second configuration the first mould surface and/or the third mould surface may be facing substantially downwards.

The method <NUM>' comprises providing <NUM> a second fabric and laying up <NUM> the second fabric on the second mould surface. Providing <NUM> the second fabric may comprise providing <NUM> a second fabric prefabricated with a tackifier. Laying up <NUM> the second fabric may comprise applying <NUM> a tackifier to the second fabric. The method <NUM>' comprises restraining <NUM> the second fabric on the second mould surface. The method <NUM>' comprises consolidating <NUM> the second fabric including heating the second mould surface to form a second pre-form laminate of the plurality of pre-form laminates. Consolidating <NUM> the second fabric may further include applying a vacuum between a second sealing member and the second mould surface.

The method <NUM>' comprises while consolidating <NUM> the second fabric and/or while consolidating <NUM> the first fabric turning <NUM> turning <NUM> the mould tool to a third configuration wherein the third mould surface is facing substantially upwards. In the third configuration the first mould surface and/or the second mould surface may be facing substantially downwards.

The method <NUM>' comprises providing <NUM> a third fabric and laying up <NUM> the third fabric on the third mould surface. Providing <NUM> the third fabric may comprise providing <NUM> a third fabric prefabricated with a tackifier. Laying up <NUM> the third fabric may comprise applying <NUM> a tackifier to the third fabric. The method <NUM>' comprises restraining <NUM> the third fabric on the third mould surface. The method <NUM>' comprises consolidating <NUM> the third fabric including heating the third mould surface to form a third pre-form laminate of the plurality of pre-form laminates. Consolidating <NUM> the third fabric may further include applying a vacuum between a third sealing member and the third mould surface.

The method <NUM>' may comprise turning <NUM> the mould tool to the first configuration and demoulding <NUM> the first pre-form laminate, e.g. while consolidating <NUM> the third fabric and/or while consolidating <NUM> the second fabric.

The method <NUM>' may comprise turning <NUM> the mould tool to the second configuration and demoulding <NUM> the second pre-form laminate, e.g. while consolidating <NUM> the third fabric.

The method <NUM>' may comprise turning <NUM> the mould tool to the third configuration and demoulding <NUM> the third pre-form laminate.

Claim 1:
A mould tool (<NUM>) for manufacturing a plurality of pre-form laminates (<NUM>) for a laminate of a wind turbine blade shell, the mould tool comprising:
- a frame (<NUM>),
- a first mould surface (<NUM>) configured for receiving a first fabric (<NUM>),
- a second mould surface (<NUM>) configured for receiving a second fabric (<NUM>), and
- a heating arrangement configured to heat the first mould surface and the second mould surface,
wherein the first mould surface (<NUM>) and/or the second mould surface (<NUM>) is curved,
characterised in that
the mould tool (<NUM>) is configured to turn between a first configuration and a second configuration, wherein in the first configuration the first mould surface (<NUM>) is facing substantially upwards, and in the second configuration the second mould surface (<NUM>) is facing substantially upwards,
in that the mould tool (<NUM>) is configured to receive the first fabric (<NUM>) on the first mould surface (<NUM>) while being in the first configuration, and
in that the mould tool (<NUM>) is configured to while the first fabric (<NUM>) is being consolidated including heating the first mould surface turn the mould tool to be in the second configuration and receive the second fabric (<NUM>) on the second mould surface (<NUM>).