Male spar beam for a segmented wind turbine blade

A method of manufacturing a male spar beam for a segmented wind turbine blade, the segmented wind turbine blade having a profiled contour including a pressure side and a suction side, and a leading edge and a trailing edge with a chordwise direction extending therebetween, the segmented wind turbine blade extending in a longitudinal direction from a root end to a tip end thereof, the method comprising the steps of:

• providing a pre-cured trailing-edge part comprising a first upper wall, a first lower wall, and a first shear wall connecting the first upper wall with the first lower wall;
• providing a pre-cured leading-edge part comprising a second shear wall, a second upper wall and a second lower wall, wherein the pre-cured leading-edge part is provided separately from the pre-cured trailing-edge part;
• and
• forming the male spar beam by attaching the first upper wall of the pre-cured leading-edge part to the second upper wall of the pre-cured trailing-edge part via an upper joint to form an upper spar cap of the male spar beam, and attaching the first lower wall of the pre-cured leading-edge part to the second lower wall of the pre-cured trailing-edge part via a lower joint to form a lower spar cap of the male spar beam, wherein the male spar beam extends in the longitudinal direction extending from a first end to a second end thereof, the second end being configured for engaging with a female receiving section of the segmented wind turbine blade,
• wherein the upper spar cap extends in the longitudinal direction, the upper spar cap having a width bounded by a left upper boundary and a right upper boundary, the upper spar cap having an upper joint arranged between the left upper boundary and the right upper boundary, and the upper spar cap being configured for facing one of the pressure side and the suction side of the segmented wind turbine blade,
• wherein the lower spar cap extends in the longitudinal direction, the lower spar cap having a width bounded by a left lower boundary and a right lower boundary, the lower spar cap having a lower joint arranged between the left lower boundary and the right lower boundary, the lower spar cap being configured for facing the other one of the pressure side and the suction side of the segmented wind turbine blade, and the lower spar cap being positioned opposite of and extending in parallel to the upper spar cap,
• wherein the pre-cured leading-edge part is formed integrally in one piece in a first female mould (100) and comprises a fibre-reinforced laminate material,
• wherein the pre-cured trailing-edge part is formed integrally in one piece in a second female mould (100) separately from the pre-cured leading-edge part and comprises a fibre-reinforced laminate material,
• wherein an end of the second lower wall of the pre-cured leading-edge part is attached to an end of the first lower wall of the pre-cured trailing-edge part to form the lower joint so that the first lower wall and the second lower wall form the lower spar cap of the male spar beam, and
• wherein an end of the second upper wall of the pre-cured leading-edge part is attached to an end of the first upper wall of the pre-cured trailing-edge part to form the upper joint so that the first upper wall and the second upper wall form the upper spar cap of the male spar beam.