Segmented wind turbine blade with spar caps

A method for manufacturing a first blade segment with a female spar part for receiving a protruding portion of a male spar part of a second blade segment for connection with the first blade segment at a chordwise joint for forming a 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 chord extending therebetween defining a chordwise direction, the segmented wind turbine blade extending in a longitudinal direction between a root end and a tip end, the method comprising:

• assembling a first shell portion and a first primary spar cap portion of a first spar cap;
• infusing the first shell portion and the first primary spar cap portion with a resin connecting the first primary spar cap portion to an inner surface of the first shell portion;
• providing the female spar part defining an inner cavity and having a longitudinal inner end and an opposite longitudinal open end towards an end face of the first blade segment;
• affixing a first secondary spar cap portion to a first outer surface of the female spar part;
• after infusing the first shell portion and the first primary spar cap portion supplying glue to the inner surface of the first shell portion, to the first primary spar cap, and/or to the first secondary spar cap portion;
• after supplying the glue arranging the first shell portion and the female spar part with the affixed first secondary spar cap portion such that the longitudinal open end of the female spar part is arranged towards an end face of the first blade segment, and such that the first secondary spar cap portion is glued to the inner surface of the first shell portion and/or to the first primary spar cap forming a glue interface between the first secondary spar cap portion and the inner surface of the first shell portion and/or the first primary spar cap;
• assembling a second shell portion and a second primary spar cap portion of a second spar cap;
• infusing the second shell portion and the second primary spar cap portion with a resin connecting the second primary spar cap portion to an inner surface of the second shell portion;
• affixing a second secondary spar cap portion to a second outer surface opposite the first outer surface of the female spar part;
• after infusing the second shell portion and the second primary spar cap portion supplying glue to an inner surface of the second shell portion, to the second primary spar cap portion, and/or to the first secondary spar cap portion;
• and
• after supplying the glue, arranging the second shell portion and the female spar part with the affixed second secondary spar cap portion such that the second secondary spar cap portion is glued to the inner surface of the second shell portion and/or to the second primary spar cap forming a glue interface between the second secondary spar cap portion and the inner surface of the second shell portion and/or the second primary spar cap,
• wherein a second blade segment connects to the first blade segment at a chordwise joint and comprises the male spar part, the male spar part having a protruding portion protruding at the chordwise joint from an end face of the second blade segment and extending through the longitudinal open end of the female spart part and into the inner cavity of the female spar part,
• wherein the first spar cap extends longitudinally over at least a majority of the extent of the first blade segment,
• wherein the second spar cap extends longitudinally over at least a majority of the extent of the first blade segment, and
• wherein the first secondary spar cap portion, at a longitudinal position of the first secondary spar cap portion, is thicker between a first edge and a first midpoint along the chordwise direction and between a second edge and a second midpoint along the chordwise direction than between the first midpoint and the second midpoint.

A first blade segment for a segmented wind turbine blade, the first blade segment having a profiled contour including a pressure side and a suction side, and a leading edge and a trailing edge with a chord extending therebetween defining a chordwise direction, the first blade segment extending in a longitudinal direction between a first end and a second end, the first blade segment comprising:

• a female spar part defining an inner cavity and having a longitudinal inner end and an opposite longitudinal open end towards an end face of the first blade segment, the female spar part being adapted to receive a protruding portion of a male spar part of a second blade segment for connection with the first blade segment at a chordwise joint for forming the segmented wind turbine blade;
• a first spar cap connected to an inner surface of a first shell portion of the first blade segment and extending longitudinally over at least a majority of the extent of the first blade segment, the first spar cap comprises a first primary spar cap portion, the first primary spar cap portion being connected to the inner surface of the first shell portion by infusion of resin, and
• a second spar cap connected to an inner surface of a second shell portion of the first blade segment and extending longitudinally over at least a majority of the extent of the first blade segment, the second spar cap comprises a second primary spar cap portion,
• wherein a first secondary spar cap portion is affixed to a first outer surface of the female spar part by infusion of resin, the first secondary spar cap portion extending longitudinally from a first end to an opposite second end arranged near the end face of the first blade segment, and wherein the first secondary spar cap portion is glued to the inner surface of the first shell portion and/or to the first primary spar cap portion forming a glue interface between the first secondary spar cap portion and the inner surface of the first shell portion and/or the first primary spar cap portion, and
• wherein the first secondary spar cap portion, at a longitudinal position of the first secondary spar cap portion, is thicker between a first edge and a first midpoint along the chordwise direction and between a second edge and a second midpoint along the chordwise direction than between the first midpoint and the second midpoint.