CN112292256A - Method of manufacturing a rotor blade component for a wind turbine - Google Patents

Abstract

The present disclosure relates to a method of manufacturing a rotor blade component of a wind turbine is disclosed. The method comprises placing at least one first pultruded component into a curved rotor blade element mould. More particularly, the first pultruded component comprises at least one design feature configured to allow the first pultruded component to be placed substantially flush against an inner surface of the curved rotor blade element mould. The method further includes placing at least one second pultruded component atop the at least one first pultruded component and infusing the first pultruded component and the second pultruded component together to form the rotor blade element.

Description

Method of manufacturing a rotor blade component for a wind turbine

Technical Field

The present subject matter relates generally to wind turbine rotor blades, and more particularly to methods for manufacturing rotor blade components (such as spar caps) for wind turbines using pultruded components.

Background

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. Modern wind turbines typically include a tower, generator, gearbox, nacelle, and one or more rotor blades. The rotor blades extract kinetic energy from the 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 directly to the generator if a gearbox is not used). The generator then converts the mechanical energy to electrical energy, which may be deployed to a utility grid.

Wind turbine rotor blades generally include a body shell formed from two shell halves of a composite laminate material. The shell halves are generally manufactured using a molding process and then coupled together along corresponding edges of the rotor blade. Generally, the body shell is relatively lightweight and has structural properties (e.g., stiffness, bending resistance, and strength) that are not configured to withstand bending moments and other loads exerted on the rotor blade during operation. In addition, wind turbine blades have become increasingly longer in order to produce more power. As a result, the blades must be more rigid and therefore heavier in order to relieve the load on the rotor.

To increase the stiffness, bending resistance, and strength of the rotor blade, the body shell is typically reinforced with one or more structural members (e.g., opposing spar caps with shear webs configured therebetween) that engage the inner surfaces of the shell halves. The spar cap may be constructed from a variety of materials, including but not limited to glass fiber laminated composites and/or carbon fiber laminated composites. However, such materials can be difficult to control, have a tendency to be flawed, and/or are highly labor intensive due to the handling of dry fabrics and the challenges of infusing large laminate structures.

Thus, modern spar caps may be constructed of prefabricated, pre-cured (e.g., pultruded) composites that may be produced in thicker sections and are typically less susceptible to defects. As used herein, the terms "pultruded composite," "pultrusion," "pultruded component," or the like generally comprise a reinforcing material (e.g., fibers or woven or braided wires) that is impregnated with a resin and pulled through a heated stent such that the resin cures or undergoes polymerization. Thus, the process of making pultruded composites typically features a continuous process that produces a composite material having a composite part with a constant cross-section. Thus, pultruded composites may eliminate various concerns and challenges associated with using dry fabrics alone.

Most pultrudes have a flat cross-section (e.g., square or rectangular) because such shapes are easy to cut and chamfer. While the use of flat pultrusion may provide significant improvements in the cost and producibility of rotor blade components, such pultrusions are typically not placed in a curved die without a gap between the pultrusion and the die shape. Conformance to the mold can be achieved to some extent by breaking the pultrusion into thinner strips; however, this increases the cost of the pultruded material, the cost of machining the pultrusion, and/or the difficulty of placing the piece into the die.

Accordingly, the art is continually seeking new and improved methods of manufacturing rotor blade components (such as spar caps) using pultrusion. More particularly, a method of manufacturing a rotor blade element using pultruded components having a specific shape corresponding to the element mould would be advantageous.

Disclosure of Invention

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In one aspect, the present disclosure is directed to a method of manufacturing a rotor blade component of a wind turbine. The method comprises placing at least one first pultruded component into a curved rotor blade element mould. More particularly, the first pultruded component comprises at least one design feature configured to allow the first pultruded component to be placed substantially flush against an inner surface of the curved rotor blade element mould. The method further includes placing at least one second pultruded component atop the at least one first pultruded component and infusing the first pultruded component and the second pultruded component together to form the rotor blade element.

In one embodiment, the rotor blade component may comprise a spar cap, a bond cap, a root ring, or any other rotor blade component having a curved shape. In another embodiment, the design features of the first pultruded component may comprise a curved surface, one or more tapered side edges, and/or a reduced width. Thus, in particular embodiments, a first side of a first pultruded component may comprise a curved surface, while an opposite surface of the pultruded component may be flat.

In further embodiments, the method may include placing a plurality of first pultruded components having a reduced width in a side-by-side configuration. In additional embodiments, the method may include placing a plurality of first pultruded components on top of each other (i.e., in a stacked configuration). In such embodiments, the lower first pultruded components may have curved surfaces, while one or more of the upper first pultruded components may have tapered side edges. Thus, when arranged together, the upper and lower first pultruded components have a shape that corresponds more closely to the inner surface of the curved rotor blade element mould than conventional rectangular pultrudates.

In yet another embodiment, the method may include placing a plurality of second pultruded components atop the planar surface of the first pultruded component. In additional embodiments, the method may include placing a plurality of second pultruded components in a side-by-side configuration (i.e., in two or more stacks) atop the first pultruded component.

In still further embodiments, the method may comprise placing one or more fibrous materials in a curved rotor blade component mould prior to placing the at least one first pultruded component, for example in order to account for deviations in the curvature of the mould.

In another aspect, the present disclosure is directed to a method of manufacturing a rotor blade component of a wind turbine. The method includes placing a plurality of wet rovings onto an inner surface of a curved rotor blade component mold. As used herein, rovings generally comprise long and narrow fiber bundles that do not combine until joined by a cured resin. The method further includes vibrating the wet rovings until they lie substantially flush against the inner surface of the curved rotor blade component mold. Further, the method includes placing at least the pultruded component atop the plurality of wet rovings. Moreover, the method includes infusing a plurality of wet rovings and pultruded components together to form the rotor blade component.

In yet another aspect, the present disclosure is directed to a rotor blade for a wind turbine. The rotor blade includes a pressure side, a suction side, a leading edge, and a trailing edge extending between a blade tip and a blade root. Additionally, the rotor blade includes a spar cap configured with at least one of the pressure side or the suction side of the rotor blade. The spar cap includes at least one first pultruded component having a design feature configured to allow the first pultruded component to be placed substantially flush against an inner surface of a curved rotor blade component mold. Further, the spar cap comprises at least one second pultruded component arranged adjacent to the at least one first pultruded component and infused with the at least one first pultruded component via the resin material. Further, it should be understood that the rotor blade may include any of the additional features as described herein.

These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention.

Drawings

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 illustrates a perspective view of an embodiment of a wind turbine according to the present disclosure;

FIG. 2 illustrates a perspective view of one of the rotor blades of FIG. 1;

FIG. 3 illustrates a cross-sectional view of the rotor blade of FIG. 2 along line 3-3;

FIG. 4 illustrates a cross-sectional view of one embodiment of a spar cap according to the present disclosure, particularly illustrating a spar cap formed from a first pultruded component having a curved surface and an opposing flat surface, wherein a plurality of second pultruded components are stacked against the flat surface of the first pultruded component;

FIG. 5 illustrates a perspective view of one of the pultruded components of the spar cap of FIG. 4;

FIG. 6 illustrates a cross-sectional view of one embodiment of a spar cap according to the present disclosure, particularly illustrating a spar cap formed from a plurality of first pultruded components having curved surfaces and/or tapered side edges, wherein a plurality of second pultruded components are stacked against the first pultruded components;

FIG. 7 illustrates a cross-sectional view of one embodiment of a spar cap according to the present disclosure, particularly illustrating a spar cap formed from a plurality of first pultruded components having a curved surface and a reduced width and arranged in a side-by-side configuration with a plurality of second pultruded components stacked against the first pultruded components;

FIG. 8 illustrates a schematic view of an embodiment of a rotor blade component mold according to the present disclosure, wherein a first pultruded component and a second pultruded component are placed in the rotor blade component mold and vacuum infused together;

FIG. 9 illustrates a flow diagram of an embodiment of a method of manufacturing a rotor blade component according to the present disclosure; and

FIG. 10 illustrates a flow diagram of another embodiment of a method of manufacturing a rotor blade component according to the present disclosure.

Detailed Description

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. It is therefore intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

In general, the present disclosure relates to a method of manufacturing a rotor blade component of a wind turbine. The method comprises placing at least one first pultruded component into a curved rotor blade element mould. More particularly, the first pultruded component comprises at least one design feature configured to allow the first pultruded component to be placed substantially flush against an inner surface of the curved rotor blade element mould. The method further includes placing at least one second pultruded component atop the at least one first pultruded component, and infusing the first and second pultruded components together (e.g., via vacuum infusion) to form the rotor blade member.

It should be noted that assembly and joining of the pultruded components may occur in a dedicated prefabricated mold (e.g., a spar cap mold), directly in a blade shell mold, or in a spar truss (beam) assembly mold, for example. It may also be appropriate to stagger the material that facilitates the infusion process during placement of the pultruded component. Moreover, in addition to vacuum infusion, the pultruded components may be joined by interleaving the pultruded components with prepreg materials, using film adhesives, and/or any other suitable joining technique.

The present disclosure provides many advantages not present in the prior art. For example, the uniquely shaped first pultruded component more readily enables a full width flat pultruded panel to be used in the construction of a rotor blade component. Thus, the method of the present disclosure provides for simpler cutting and beveling operations due to fewer pultrudates. Thus, the method of the present disclosure also provides for a simpler process of cutting and/or beveling a complete stack of pultruded components. In addition, the methods described herein reduce bending of flat pultruded components under vacuum pressure.

Referring now to the drawings, FIG. 1 illustrates a perspective view of a horizontal-axis wind turbine 10. It should be appreciated thatwind turbine 10 may also be a vertical axis wind turbine. As shown in the illustrated embodiment, thewind turbine 10 includes atower 12, anacelle 14 mounted on thetower 12, and arotor hub 18 coupled to thenacelle 14. Thetower 12 may be made of tubular steel or other suitable material.Rotor hub 18 includes one ormore rotor blades 16 coupled tohub 18 and extending radially outward fromhub 18. As shown,rotor hub 18 includes threerotor blades 16. However, in alternative embodiments,rotor hub 18 may include more or less than threerotor blades 16. Therotor blades 16 rotate therotor hub 18 to enable kinetic energy to be converted from wind into usable mechanical energy, and subsequently, electrical energy. In particular, thehub 18 may be rotatably coupled to a generator (not shown) positioned within thenacelle 14 for generating electrical energy.

Referring to FIGS. 2 and 3, one of therotor blades 16 of FIG. 1 is illustrated in accordance with aspects of the present subject matter. In particular, FIG. 2 illustrates a perspective view of therotor blade 16, while FIG. 3 illustrates a cross-sectional view of therotor blade 16 along the cross-sectional line 3-3 shown in FIG. 2. As shown, therotor blade 16 generally includes ablade root 30 configured to be mounted or otherwise secured to the hub 18 (FIG. 1) of thewind turbine 10, and ablade tip 32 disposed opposite theblade root 30. Thebody shell 21 of the rotor blade extends substantially along thelongitudinal axis 27 between theblade root 30 and theblade tip 32. Thebody shell 21 may generally serve as an outer shell/shroud for therotor blade 16 and may define a substantially aerodynamic profile, such as by defining a symmetrical or curved airfoil-shaped cross-section. Thebody shell 21 may also define apressure side 34 and asuction side 36 extending between theforward end 26 and theaft end 28 of therotor blade 16. Further, therotor blade 16 may also have aspan 23 defining the total length between theblade root 30 and theblade tip 32, and achord 25 defining the total length between theleading edge 26 and the trailingedge 28. As generally understood, thechord 25 may generally vary in length with respect to thespan 23 as therotor blade 16 extends from theblade root 30 to theblade tip 32.

In several embodiments, thebody shell 21 of therotor blade 16 may be formed as a single, unitary member. Alternatively, thebody case 21 may be formed of a plurality of case members. For example, thebody shell 21 may be fabricated from a first shell half that generally defines apressure side 34 of therotor blade 16 and a second shell half that generally defines asuction side 36 of therotor blade 16, with such shell halves being secured to one another at the forward and aft ends 26, 28 of theblade 16. Additionally,body housing 21 may generally be formed from any suitable material. For example, in one embodiment, thebody shell 21 may be formed entirely of 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 thebody shell 21 may be constructed as a layered structure and may include a core formed of a lightweight material such as wood (e.g., balsa wood), foam (e.g., extruded polystyrene foam), or a combination of such materials disposed between the laminated composite layers.

With particular reference to FIG. 3, therotor blade 16 may also include one or more longitudinally extending structural members configured to provide increased stiffness, bending resistance, and/or strength to therotor blade 16. For example, therotor blade 16 may include a pair of longitudinally extending spar caps 22, 20 configured to engage against opposinginner surfaces 35, 37 of the pressure andsuction sides 34, 36, respectively, of therotor blade 16. Additionally, one ormore shear webs 24 may be disposed between the spar caps 20, 22 to form a truss-like configuration. The spar caps 20, 22 may generally be designed to control bending stresses and/or other loads acting on therotor blade 16 in a generally spanwise direction (a direction parallel to thespan 23 of the rotor blade 16) during operation of thewind turbine 10. Similarly, the spar caps 20, 22 may also be designed to withstand spanwise compression that occurs during operation of thewind turbine 10.

The methods of manufacturing rotor blade components as described herein may be applied to any suitable rotor blade component. For example, in one embodiment, the rotor blade component may include a spar cap, a bond cap, a root ring, or any other rotor blade component having a curved shape. In other words, a rotor blade component as described herein typically comprises an aerodynamic shape and is composed of a unique pultrusion which more closely corresponds to the aerodynamic shape of the component on one side and is flat on the opposite side. While aunique pultruded component 40 is illustrated as being used to form thespar cap 22, it should also be understood that thepultruded component 40 as described herein may be used to construct a variety of other rotor blade components in addition to thespar cap 22.

Referring now to fig. 4 and 6-7, various embodiments of aspar cap 22 according to the present disclosure are shown. More particularly, as shown, a cross-sectional view of aspar cap 22 constructed from a plurality ofpultruded components 40 or panels arranged in layers in accordance with the present disclosure is shown. For example, as shown in the illustrated embodiment, each of thepultruded components 40 may form a single layer of thespar cap 22. The layers are then stacked on top of each other and joined together using any suitable means (e.g., via vacuum infusion). In addition, FIG. 5 illustrates one of thepultruded components 40 formed from aresin material 44 reinforced with one ormore fiber materials 42.

Referring particularly to fig. 4 and 6-7, thespar cap 22 includes: at least onefirst pultruded component 46 having a design feature configured to allow thefirst pultruded component 46 to be placed substantially flush against an inner surface of the curved rotor blade component mold; and at least one flat secondpultruded component 52 arranged with thefirst pultruded component 46. Further, thefirst pultruded component 46 and thesecond pultruded component 52 are infused together via a resin material. For example, in one embodiment, the resin material may comprise a thermoplastic material or a thermoset material.

Thermoplastic materials as described herein generally comprise plastic materials or polymers that are reversible in nature. For example, thermoplastic materials typically become pliable or moldable when heated to a certain temperature and solidify upon cooling. Further, the thermoplastic material may include an amorphous thermoplastic material and/or a semi-crystalline thermoplastic material. For example, some amorphous thermoplastic materials may generally include, but are not limited to, styrene, vinyl, cellulose, polyester, acrylic, polysulfone, and/or imide. More particularly, exemplary amorphous thermoplastic materials may include polystyrene, Acrylonitrile Butadiene Styrene (ABS), polymethyl methacrylate (PMMA), saccharified (glycolinked) polyethylene terephthalate (PET-G), polycarbonate, polyvinyl acetate, amorphous polyamide, polyvinyl chloride (PVC), polyvinylidene chloride, polyurethane, or any other suitable amorphous thermoplastic material. Additionally, exemplary semi-crystalline thermoplastic materials may generally include, but are not limited to, polyolefins, polyamides, fluoropolymers, ethyl acrylates, polyesters, polycarbonates, and/or acetals. More particularly, exemplary semi-crystalline thermoplastic materials may include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polypropylene, polyphenylene sulfide, polyethylene, polyamide (nylon), polyether ketone, or any other suitable semi-crystalline thermoplastic material.

Furthermore, thermoset materials as described herein generally comprise plastic materials or polymers that are irreversible in nature. For example, thermoset materials, once cured, cannot be easily reshaped or returned to a liquid state. Thus, after initial formation, the thermoset material is substantially resistant to heat, corrosion, and/or creep. Exemplary thermosets may generally include, but are not limited to, some polyesters, esters, epoxies, or any other suitable thermosets.

Still referring to fig. 4, 6, and 7, the design features of thefirst pultruded component 46 may include acurved surface 48, one or more tapered side edges 58, or a reduced width W. For example, as shown in FIG. 4, thespar cap 22 includes a singlefirst pultruded component 46 having a first side with acurved surface 48, while anopposite surface 50 of thepultruded component 46 may be flat.

In additional embodiments, as shown in fig. 6, thespar cap 22 may include a plurality of firstpultruded components 46 stacked against one another. In such embodiments, the one or more lower firstpultruded components 54 may have acurved surface 48, while the one or more upper firstpultruded components 56 may have tapered side edges 58. For example, as shown, thespar cap 22 includes one lowerfirst pultruded component 54 and two additional upper firstpultruded components 56, with tapered side edges 58 stacked atop the lowerfirst pultruded component 54. As such, thecurved surface 48 and the taperededge 58 are configured to lie flush with the component mold during manufacturing, which is discussed in more detail herein. In other embodiments, the spar caps 22 may include any number of upper and/or lower first pultruded components in order to achieve a desired thickness of the component. Additionally, as shown in fig. 4 and 6-7, thespar cap 22 may include a plurality of secondpultruded components 52 that are arranged or stacked against theplanar surface 50 of thefirst pultruded component 46.

Referring particularly to FIG. 7, thespar cap 22 may also include a plurality of firstpultruded components 46 of reduced width W arranged in a side-by-side configuration. As used herein, the reduced width W generally refers to a width that is less than the overall width of the spar cap 22 (or any other rotor blade component). Thus, by providing a plurality of firstpultruded components 46 with a reduced width W and/or more than one shape,spar cap 22 may be able to better conform to the shape ofinner surface 63 ofcomponent mold 60 during manufacture of the part. Additionally, as shown, thespar cap 22 may also include a plurality of secondpultruded components 52 arranged or stacked in a side-by-side configuration against the firstpultruded components 46. For example, as shown in FIG. 7, two stacks of flat secondpultruded components 52 form spar caps 22 to better conform to the shape of theinner surface 63 of thecomponent mold 60 during the manufacturing process.

Referring now to FIG. 9, a flow diagram of an embodiment of amethod 100 of manufacturing a rotor blade component of awind turbine 10 is disclosed. For example, as mentioned, the rotor blade component may include a spar cap, a bond cap, a root ring, or any other rotor blade component having a curved shape. As shown at 102, themethod 100 includes placing at least onefirst pultruded component 46 into a curved rotor blade element mold 60 (FIG. 8). More particularly, as mentioned, thefirst pultruded component 46 includes at least one design feature configured to allow thefirst pultruded component 46 to be placed substantially flush against theinner surface 63 of the curved rotorblade element mold 60. For example, in one embodiment, the design features of thefirst pultruded component 46 may include a curved surface, one or more tapered side edges 58, or a reduced width W. Thus, in particular embodiments, a first side of thefirst pultruded component 46 may include acurved surface 48 while anopposite surface 50 of thepultruded component 46 may be flat. In further embodiments, themethod 100 may include placing a plurality of first pultruded components 46 (fig. 7) having a reduced width W in a side-by-side configuration. In additional embodiments, as shown in fig. 6, themethod 100 may include placing a plurality of firstpultruded components 46 atop one another. In such embodiments, as mentioned, the lower firstpultruded components 54 may havecurved surfaces 48, while one or more upper firstpultruded components 56 may have tapered side edges 58.

Still referring to FIG. 9, themethod 100 further includes placing at least one flat secondpultruded component 52 atop thefirst pultruded component 46, as shown at 104. In yet another embodiment, themethod 100 may include placing a plurality of flat secondpultruded components 52 atop theflat surface 50 of thefirst pultruded component 46. More particularly, as shown in fig. 7, themethod 100 may include placing a plurality of flat secondpultruded components 52 in a side-by-side configuration atop the firstpultruded components 52.

Once thefirst pultruded component 46 and thesecond pultruded component 52 are arranged in the curved rotorblade element mold 60 in the desired configuration, themethod 100 includes infusing thefirst pultruded component 46 and thesecond pultruded component 52 together to form the rotor blade element, as shown at 106 of FIG. 9. More particularly, as mentioned, thefirst pultruded component 46 and thesecond pultruded component 52 may be infused together via vacuum infusion using anysuitable resin material 44. For example, as shown in FIG. 8, once thefirst pultruded component 46 and thesecond pultruded component 52 are arranged in the curved rotorblade component mold 60 in the desired configuration, avacuum bag 64 may be secured atop themold 60 and the vacuum pressure may be used to drive theresin material 44 into themold 60 via aresin supply line 65 to form thespar cap 22.

In additional embodiments, themethod 100 may further include placing one or more fibers orprepregs 62 in the curved rotorblade component mold 60 prior to placing thefirst pultruded component 46 in the curved rotorblade component mold 60, for example, to account for deviations in the curvature of the mold. More particularly, in certain embodiments, thefibrous material 62 may include glass fibers, carbon fibers, polymer fibers, ceramic fibers, nanofibers, metal fibers, or the like. Further, in particular embodiments, the prepreg material may include carbon or glass fibers pre-impregnated with epoxy resin, vinsnester (vylnester), polyester, or other suitable thermosetting or thermoplastic resins.

Referring now to FIG. 10, a flow diagram of another embodiment of amethod 200 of manufacturing a rotor blade component ofwind turbine 10 is disclosed. As shown at 202,method 200 includes placing a plurality of wet rovings onto an inner surface of a curved rotor blade component mold. As shown at 204, themethod 200 includes vibrating the wet roving until the roving lies substantially flush against the inner surface of the curved rotor blade component mold. More particularly, in certain embodiments, the wet roving may be vibrated using a shroud plate (caul plate) or a pultruded component. In addition, similar to the sheathing, one or more flatpultruded components 40 may be placed on top of the wet roving. As shown at 206, themethod 200 includes placing at least one pultruded component atop a plurality of wet rovings. As shown at 208, themethod 200 includes infusing a plurality of wet rovings and pultruded components together to form a rotor blade component.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims (20)

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

placing at least one first pultruded component into a curved rotor blade element mold, the first pultruded component comprising at least one design feature configured to allow the first pultruded component to be placed substantially flush against an inner surface of the curved rotor blade element mold;

placing at least one second pultruded component atop said at least one first pultruded component; and

infusing the first pultruded component and the second pultruded component together to form the rotor blade element.

2. The method of claim 1, wherein the rotor blade component comprises at least one of a spar cap, a bond cap, or a root ring.

3. The method of claim 1, wherein the at least one design feature comprises at least one of a curved surface, one or more tapered side edges, or a reduced width.

4. The method of claim 3, wherein a first side of the at least one first pultruded component comprises the curved surface and an opposite surface is flat.

5. The method of claim 1, further comprising placing a plurality of first pultruded components having a reduced width in a side-by-side configuration.

6. The method of claim 1, further comprising placing a plurality of first pultruded components on top of each other.

7. The method of claim 6, wherein the lower first pultruded components comprise curved surfaces and one or more of the upper first pultruded components comprise tapered side edges.

8. The method of claim 4, further comprising placing a plurality of second pultruded components atop the planar surface of the at least one first pultruded component.

9. The method of claim 8, further comprising placing the plurality of second pultruded components atop the at least one first pultruded component in a side-by-side configuration.

10. The method of claim 1, further comprising placing one or more fiber materials in the curved rotor blade component mold prior to placing the at least one first pultruded component.

11. A method of manufacturing a rotor blade component of a wind turbine, the method comprising:

placing a plurality of wet rovings onto an inner surface of a curved rotor blade component mold;

vibrating the wet roving until the roving lies substantially flush against an inner surface of the curved rotor blade component mold;

placing at least one pultruded component atop the plurality of wet rovings; and

infusing the plurality of wet rovings and the at least one pultruded component together to form the rotor blade member.

12. A rotor blade of a wind turbine, comprising:

a pressure side, a suction side, a leading edge and a trailing edge extending between a blade tip and a blade root; and

a spar cap configured with at least one of the pressure side or the suction side, the spar cap comprising:

at least one first pultruded component comprising a design feature configured to allow the first pultruded component to be placed substantially flush against an inner surface of a curved rotor blade element mold;

at least one second pultruded component adjacent to the at least one first pultruded component and infused with the at least one first pultruded component via a resin material.

13. The rotor blade of claim 12, wherein the at least one design feature comprises at least one of a curved surface, one or more tapered side edges, or a reduced width.

14. The rotor blade of claim 13, wherein a first side of the at least one first pultruded component comprises the curved surface and an opposite surface is flat.

15. The rotor blade of claim 12, wherein the spar cap further comprises a plurality of first pultruded components of reduced width arranged in a side-by-side configuration.

16. The rotor blade according to claim 12, wherein the spar cap further comprises a plurality of first pultruded components stacked on top of each other.

17. The rotor blade of claim 16, wherein the lower first pultruded component comprises a curved surface and the one or more upper first pultruded components comprise tapered side edges.

18. The rotor blade according to claim 12, wherein the spar cap further comprises a plurality of second pultruded components stacked against the at least one first pultruded component.

19. The rotor blade according to claim 18, wherein the plurality of second pultruded components are stacked in a side-by-side configuration against the at least one first pultruded component.

20. The rotor blade of claim 12, wherein the at least one resin material further comprises at least one of a thermoplastic material or a thermoset material.

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