Composite component having safety edge

Abstract

A composite component ( 130 ) such as a shear web for a wind turbine blade is described. The component comprises a molded laminate ( 44 ) formed from one or more fibrous layers ( 40 ) integrated by resin and defining a laminate edge ( 48 ). An edging strip ( 60 ) is located adjacent to the laminate edge ( 48 ) and is integrated with the laminate. In a particular example, the edging ( 60 ) is made from closed-cell foam. Accordingly, resin does not permeate into the bulk of the edging ( 60 ) during the molding process. After the molding process, a portion ( 60 a ) of the edging ( 60 ) is removed to reveal an exposed, substantially resin-free surface of the edging which defines a safety edge ( 64 ) of the component.

The invention claimed is: 
     
       1. A method of making a composite component for a wind turbine blade, the composite component having a safety edge, and the method comprising:
 arranging one or more fibrous layers in a mould such that the layers define a laminate edge; 
 arranging an edging adjacent to the laminate edge; 
 integrating the fibrous layers and the edging by means of resin; 
 substantially preventing the resin from permeating into the edging; and 
 removing a portion of the edging to reveal a substantially resin-free exposed surface of the edging that defines a safety edge of the component, the removing step comprising:
 severing the edging along a severance line spaced apart from the laminate edge; and 
 removing a sacrificial portion of the edging outboard of the severance line such that a shield portion of the edging inboard of the severance line remains integrated with the laminate and includes the substantially resin-free exposed surface defining the safety edge of the component. 
 
 
     
     
       2. The method of  claim 1 , wherein the edging is made from substantially resin impermeable material such that the resin is substantially prevented from permeating into the edging. 
     
     
       3. The method of  claim 1 , further comprising arranging a plurality of fibrous layers, one on top of the other, in the mould to form the laminate. 
     
     
       4. The method of  claim 1 , comprising removably fixing the edging to the mould. 
     
     
       5. The method of  claim 1 , comprising arranging a peel ply layer on the mould, and arranging the fibrous layers and the edging over the peel ply layer. 
     
     
       6. The method of  claim 1 , comprising arranging a peel ply layer over the fibrous layers and the edging. 
     
     
       7. The method of  claim 1 , wherein an initial thickness of the edging is equal to or greater than an initial combined thickness of the fibrous layer(s) and the method further comprises compressing the fibrous layer(s) and the edging during a vacuum-assisted moulding process such that the edging has a final thickness that is substantially the same as a final combined thickness of the fibrous layer(s). 
     
     
       8. The method of  claim 1 , further comprising supplying liquid resin to the mould. 
     
     
       9. The method of  claim 1 , further comprising integrating the fibrous layers and the edging by curing the resin. 
     
     
       10. A composite component made according to the method of  claim 1 . 
     
     
       11. A shear web made according to the method of  claim 1 . 
     
     
       12. A wind turbine blade comprising the shear web of  claim 11 . 
     
     
       13. A wind turbine comprising the wind turbine blade of  claim 12 . 
     
     
       14. A composite component for a wind turbine blade comprising:
 a laminate formed from one or more fibrous layers and a resin, the laminate having a laminate edge defined by an edge of the one or more fibrous layers; and 
 an edging located adjacent to the laminate edge and integrated with the laminate by the resin; 
 wherein the edging has a substantially resin-free exposed surface that defines a safety edge of the composite component; 
 wherein the edging is made from a substantially resin impermeable material; and 
 wherein the edging defines a surface and internal core material, the resin-free exposed surface being formed by the internal core material of the edging by severance of the edging along a severance line. 
 
     
     
       15. The composite component of  claim 14 , wherein the edging comprises foam, balsa and/or polystyrene. 
     
     
       16. The composite component of  claim 15 , wherein the edging is made from a closed-cell foam. 
     
     
       17. The composite component of  claim 14 , wherein the edging is in the form of a strip. 
     
     
       18. The composite component of  claim 14 , wherein the edging is made from a compressible material. 
     
     
       19. The composite component of  claim 18 , wherein the edging is in a compressed state. 
     
     
       20. The composite component of  claim 14 , further comprising a peel ply layer arranged over the laminate and the edging. 
     
     
       21. The composite component of  claim 14 , wherein the safety edge of the composite component is formed by severing the edging along a severance line and removing a sacrificial portion of the edging outboard of the severance line to reveal the substantially resin-free exposed surface of the edging. 
     
     
       22. The composite component of  claim 14 , wherein the component is formed by means of VARTM. 
     
     
       23. The composite component of  claim 14 , wherein the component is a shear web. 
     
     
       24. A wind turbine blade comprising the composite component of  claim 14 . 
     
     
       25. A wind turbine comprising the wind turbine blade of  claim 24 .