Preform spar cap for a wind turbine rotor blade

1. A spar cap, comprising:

a plurality of preform components configured to be affixed together in an end-to-end arrangement successively along a length of a rotor blade for forming a spar cap;

wherein:

said plurality of preform components each has a swept shape;

said plurality of preform components each has a first end and a second end;

said plurality of preform components are joined by mating said second end of a first preform component to said first end of a next preform component generally aligning along the length of the rotor blade;

an angle of said first end is supplementary to an angle of said second end, wherein mating said second end of said first preform component with said first end of said next preform component comprises a scarf joint; and

further comprising at least one pin, wherein said at least one pin extends through said first preform component and said next preform component forming said scarf joint.

2. The spar cap of claim 1 , wherein said spar cap is integrated with a first shell of a rotor blade and further comprises:

a shear web attached to the inner surface of said first shell and generally aligned with said spar cap; and

a second shell having a second spar cap integrated therein and joined to said first shell, wherein said shear web is attached to said second shell and is generally aligned with said second spar cap.

3. The spar cap of claim 1 , wherein the swept shape of each of said plurality of preform components defines an arc between said first end and said second end of the respective preform component, wherein said arc generally follows a portion of a swept shape of the rotor blade from its distal end to its proximal end.

4. The spar cap of claim 1 , further comprising a joint interface layer, wherein said joint interface layer exists between said first end and said second end, and wherein said joint interface layer is a polymer material.

5. The spar cap of claim 1 , further comprising:

at least one facing ply, wherein:

said at least one facing ply communicates with at least one side of said spar cap;

said at least one facing ply overlaps said first end and said second end; and

said at least one facing ply is a polymer material.

6. A spar cap, comprising:

a plurality of preform components configured to be affixed together in an end-to-end arrangement successively along a length of a rotor blade for forming a spar cap;

wherein:

said plurality of preform components each has a swept shape;

said plurality of preform components each has a first end and a second end;

said plurality of preform components are joined by mating said second end of a first preform component to said first end of a next preform component generally aligning along the length of the rotor blade; and

further comprising a joint interface layer, wherein said joint interface layer exists between said first end and said second end, and wherein said joint interface layer is a polymer material.

7. The spar cap of claim 6 , wherein said joint interface layer further comprises a fibrous substrate.

8. The spar cap of claim 6 , wherein the swept shape of each of said plurality of preform components defines an arc between said first end and said second end of the respective preform component, wherein said arc generally follows a portion of a swept shape of the rotor blade from its distal end to its proximal end.

9. The spar cap of claim 6 , wherein said spar cap is integrated with a first shell of a rotor blade and further comprises:

a shear web attached to the inner surface of said first shell and generally aligned with said spar cap; and

a second shell having a second spar cap integrated therein and joined to said first shell, wherein said shear web is attached to said second shell and is generally aligned with said second spar cap.

10. The spar cap of claim 6 , further comprising at least one pin, wherein said at least one pin extends through said first preform component and said next preform component.

11. The spar cap of claim 6 , further comprising:

at least one facing ply, wherein:

said at least one facing ply communicates with at least one side of said spar cap;

said at least one facing ply overlaps said first end and said second end; and

said at least one facing ply is a polymer material.

12. A spar cap, comprising:

a plurality of preform components configured to be affixed together in an end-to-end arrangement successively along a length of a rotor blade for forming a spar cap;

wherein:

said plurality of preform components each has a swept shape;

said plurality of preform components each has a first end and a second end;

said plurality of preform components are joined by mating said second end of a first preform component to said first end of a next preform component generally aligning along the length of the rotor blade; and

further comprising:

at least one facing ply,

wherein:

said at least one facing ply communicates with at least one side of said spar cap;

said at least one facing ply overlaps said first end and said second end; and

said at least one facing ply is a polymer material.

13. The spar cap of claim 12 , wherein said at least one facing ply further comprises a fibrous substrate.

14. The spar cap of claim 12 , wherein the swept shape of each of said plurality of preform components defines an arc between said first end and said second end of the respective preform component, wherein said arc generally follows a portion of a swept shape of the rotor blade from its distal end to its proximal end.

15. The spar cap of claim 12 , wherein said spar cap is integrated with a first shell of a rotor blade and further comprises:

a shear web attached to the inner surface of said first shell and generally aligned with said spar cap; and

a second shell having a second spar cap integrated therein and joined to said first shell, wherein said shear web is attached to said second shell and is generally aligned with said second spar cap.

16. The spar cap of claim 12 , further comprising at least one pin, wherein said at least one pin extends through said first preform component and said next preform component.

17. The spar cap of claim 12 , further comprising a joint interface layer, wherein said joint interface layer exists between said first end and said second end, and wherein said joint interface layer is a polymer material.

18. A method for forming a spar cap, comprising:

aligning a plurality of preform components having a swept shape comprising a first end and a second end for forming a spar cap, wherein said second end of a first preform component aligns with said first end of a next preform component, wherein said plurality of preform components are configured to be affixed together in an end-to-end arrangement successively along a length of a rotor blade;

joining said aligned plurality of preform components generally aligning along the length of the rotor blade; and

interposing a joint interface layer, wherein said joint interface layer exists between said first end of said first preform component and said second end of sad next preform component, and wherein said joint interface layer is a polymer material.

19. The method of claim 18 , further comprising inserting at least one pin through said first preform component and said next preform component where joined.

20. The method of claim 18 , further comprising:

attaching at least one facing ply,

wherein:

said at least one facing ply communicates with at least one side of said spar cap;

said at least one facing ply overlaps said first end and said second end; and

said at least one facing ply is a polymer material.

21. The method of claim 18 , further comprising:

laying said plurality of preform components over a convex form;

wherein said convex form has substantially the same arcuate shape as a rotor blade into which said spar cap will be integrated; and

wherein laying said plurality of preform components over said convex form causes said plurality of preform components to be shaped into substantially the same arcuate shape as said rotor blade into which said spar cap will be integrated.

22. The method of claim 21 , further comprising aligning said plurality of preform components with at least one alignment fence, wherein said at least one alignment fence:

communicates with said convex form;

substantially extends the length of said convex form; and

assists to align said plurality of preform components by abutting contiguous edges of said plurality of preform components.

23. The method of claim 22 , further comprising aligning said plurality of preform components with at least one alignment marking.

24. The method of claim 23 , further comprising:

placing said aligned plurality of preform components under vacuum; and

applying heat to cure said aligned plurality of preform components.

25. The method of claim 18 , further comprising:

integrating said spar cap with a first shell of a rotor blade;

aligning a shear web substantially with said spar cap;

attaching said shear web to the inner surface of said first shell;

integrating a second spar cap to a second shell of a rotor blade;

joining said second shell to said first shell, wherein said shear web attaches to said second shell and generally aligns with said second spar cap.