Methods for manufacturing spar caps for wind turbine rotor blades

1. A method for manufacturing a rotor blade of a wind turbine, the method comprising:

forming an outer frame of a first spar cap of the rotor blade via at least one of three-dimensional (3D) pultrusion, thermoforming, or 3D printing, the outer frame having a varying cross-section that corresponds to a varying cross-section of the rotor blade along a span thereof, the outer frame being formed with extended side edges;

arranging a plurality of structural materials within the outer frame of the first spar cap, the plurality of structural materials comprising at least one of thermoplastic or thermoset plies or pultruded members;

folding the extended side edges towards a center of the outer frame so as to retain the plurality of structural materials therein;

securing the plurality of structural materials and the outer frame together so as to form the first spar cap; and,

attaching a base of the outer frame to an inner surface of at least one of a pressure side or a suction side of the rotor blade.

2. The method of claim 1 , wherein attaching the base of the outer frame to the inner surface of at least one of the pressure side or the suction side of the rotor blade further comprises:

laying at least one outer skin layer of at least one of the pressure side or the suction side of the rotor blade into a shell mold;

placing the outer frame of the first spar cap adjacent to the outer skin;

laying at least one inner skin layer of at least one of the pressure side or the suction side of the rotor blade atop the first spar cap; and,

infusing the first spar cap between the outer and inner skin layers.

3. The method of claim 1 , further comprising

forming a second spar cap;

joining one of the first and second spar caps to the pressure side and the other of the first and second spar caps to the suction side; and,

securing a shear web between the first and second spar caps.

4. The method of claim 1 , wherein forming the outer frame of the spar cap further comprises pultruding the outer frame from at least one of a thermoplastic material or a thermoset material, the thermoplastic material and the thermoset material being reinforced with one or more fiber materials, wherein the one or more fiber materials comprise at least one of glass fibers, carbon fibers, metal fibers, polymer fibers, ceramic fibers, nanofibers, wood fibers, bamboo fibers, or combinations thereof.

5. The method of claim 1 , further comprising attaching one or more straps to the extended side edges of the outer frame of the spar cap and placing the spar cap into the shell mold via the one or more straps.

6. The method of claim 1 , further comprising attaching one or more straps around the outer frame of the spar cap and placing the spar cap into the shell mold via the one or more straps.

7. The method of claim 1 , further comprising arranging a plurality of layers of the structural materials within the outer frame of the spar cap and arranging one or more non-structural layers between the layers of structural materials, the one or more non-structural materials comprising at least one of a glass veil, a continuous fiber mat, or a fabric material.

8. A method for manufacturing a rotor blade of a wind turbine, the method comprising:

forming an outer frame of a spar cap having extended side edges;

machining a plurality of structural materials, the plurality of structural materials comprising at least one of thermoplastic or thermoset plies or pultruded members;

dispensing the plurality of structural materials directly into the outer frame of the spar cap after machining;

folding the side edges away from a center of the outer frame to create opposing flanges;

infusing the plurality of structural materials and the outer frame together via at least one of a thermoplastic or thermoset resin material so as to form the spar cap; and,

securing the flanges to an inner surface of at least one of a pressure side or a suction side of the rotor blade.

9. The method of claim 8 , wherein securing the flanges to the inner surface of at least one of the pressure side or the suction side of the rotor blade further comprises:

laying at least one outer skin layer of at least one of the pressure side or the suction side of the rotor blade into a shell mold;

placing the outer frame of the spar cap adjacent to the outer skin;

laying at least one inner skin layer of at least one of the pressure side or the suction side of the rotor blade atop the flanges of the outer frame; and,

infusing the flanges of the outer frame between the outer and inner skin layers.

10. The method of claim 8 , wherein forming the outer frame of the spar cap having the extended side edges further comprises pultruding the outer frame from at least one of a thermoplastic material or a thermoset material, the thermoplastic material and the thermoset material being reinforced with one or more fiber materials, wherein e one or more fiber materials comprise at least one of glass fibers, carbon fibers, metal fibers, polymer fibers, ceramic fibers, nanofibers, wood fibers, bamboo fibers, or combinations thereof.

11. The method of claim 8 , further comprising attaching one or more straps to the extended side edges of the outer frame of the spar cap and placing the spar cap into the shell mold via the one or more straps.

12. The method of claim 8 , further comprising attaching one or more straps around the outer frame of the spar cap and placing the spar cap into the shell mold via the one or more straps.