Rotor blades having structural skin insert and methods of making same

Abstract

The present disclosure is directed to a method of manufacturing a rotor blade for a wind turbine. The method includes providing a blade mold of the rotor blade. Another step includes placing an outer skin layer in the blade mold. The method also includes placing one or more structural inserts in the blade mold atop the outer skin layer as a function of a load of the rotor blade. Further, each of the structural inserts includes a plurality of cells arranged in a predetermined pattern. Further, the cells have varying cell sizes. The method also includes placing an inner skin layer atop the one or more structural inserts and securing the outer skin layer, the one or more structural inserts, and the inner skin layer together to form the rotor blade.

Dependencies are inferred from the claim text.