WO2021163875A1 - 用于风机叶片的主梁及其制造方法 - Google Patents

用于风机叶片的主梁及其制造方法 Download PDF

Info

Publication number
WO2021163875A1
WO2021163875A1 PCT/CN2020/075678 CN2020075678W WO2021163875A1 WO 2021163875 A1 WO2021163875 A1 WO 2021163875A1 CN 2020075678 W CN2020075678 W CN 2020075678W WO 2021163875 A1 WO2021163875 A1 WO 2021163875A1
Authority
WO
WIPO (PCT)
Prior art keywords
carbon fiber
main beam
inlay
resin
fiber pultruded
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2020/075678
Other languages
English (en)
French (fr)
Inventor
梁嫄
欧弗高·拉尔斯
孙建旭
庄雷
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Envision Energy Co Ltd
Original Assignee
Envision Energy Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to PL20919545.2T priority Critical patent/PL4108908T3/pl
Priority to BR112022016449-1A priority patent/BR112022016449B1/pt
Priority to RS20250924A priority patent/RS67232B1/sr
Priority to AU2020430267A priority patent/AU2020430267B2/en
Priority to EP20919545.2A priority patent/EP4108908B1/en
Priority to PCT/CN2020/075678 priority patent/WO2021163875A1/zh
Priority to CN202080003501.9A priority patent/CN113544379A/zh
Priority to US17/795,541 priority patent/US11905921B2/en
Priority to ES20919545T priority patent/ES3040236T3/es
Application filed by Envision Energy Co Ltd filed Critical Envision Energy Co Ltd
Publication of WO2021163875A1 publication Critical patent/WO2021163875A1/zh
Priority to SA522440165A priority patent/SA522440165B1/ar
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Images

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/065—Rotors characterised by their construction elements
    • F03D1/0675—Rotors characterised by their construction elements of the blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
    • B29K2309/08—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082—Blades, e.g. for helicopters
    • B29L2031/085—Wind turbine blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2230/00—Manufacture
    • F05B2230/30—Manufacture with deposition of material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/60—Properties or characteristics given to material by treatment or manufacturing
    • F05B2280/6003—Composites; e.g. fibre-reinforced
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/60—Properties or characteristics given to material by treatment or manufacturing
    • F05B2280/6013—Fibres
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present invention generally relates to the field of wind power generators, and in particular, to a main beam used for wind turbine blades. In addition, the present invention also relates to a method for manufacturing such a main beam.
  • the blades of a wind turbine are important components for wind turbines to capture wind energy.
  • the blades installed on the hub of the wind turbine rotate under the drive of wind energy to generate lift, which is further converted into torque through the transmission chain in the nacelle to drive the generator to generate electricity.
  • the larger the impeller formed by the blades the more wind energy that can be captured, so the blades of the fan tend to be longer and longer.
  • the headroom (clearance refers to the distance from the tip of the wind turbine blade to the tower, which is an important safety indicator) has become a bottleneck.
  • the development of new blade materials or blade designs to improve the headroom is imminent.
  • the main beam of the blade is a component that contributes about 90% of the swing stiffness, which basically determines the size of the headroom.
  • Carbon fiber is a high-modulus and high-strength material, but it is also expensive. Therefore, how to reasonably introduce carbon fiber into the blades to increase the headroom and minimize the cost of the blades is an important current research topic for major wind power companies. Because the cost of the pure carbon fiber main beam is too high, and the one-time investment return time is too long, so a variety of mixed carbon fiber materials have emerged. Hybrid carbon fiber materials are produced by adding a certain amount of carbon fiber to traditional glass fiber materials. Hybrid carbon fiber materials can balance performance and cost as much as possible.
  • the current hybrid carbon fiber materials mainly have the following limitations:
  • the mixing method of mixed carbon fiber materials is mostly carried out at the material level.
  • carbon fiber and glass fiber are mixed and woven on the same fabric layer in different proportions of fiber bundles, or a layer of carbon fiber and a layer of glass fiber are mixed, such a hybrid form
  • Extremely lack of design freedom, the proportion of fiber mixing is completely restricted by the material supplier.
  • only fixed mixing ratio materials can be selected, which cannot meet the needs of customization for each model.
  • Carbon-glass hybrid materials that is, a mixture of carbon fiber and glass fiber
  • the infusion process that is, the carbon-glass hybrid fabric is superimposed and poured together, or several layers of carbon fiber and several glass fiber cloth are superimposed and poured together.
  • the pouring process of this material is prone to defects such as bubbles and wrinkles, which greatly compromises the final performance.
  • the task of the present invention is to provide a main beam for wind turbine blades and a manufacturing method thereof.
  • various properties of the blade such as stiffness, can be adjusted while reducing the amount of carbon fiber.
  • this task is solved by a main beam for wind turbine blades, the main beam including:
  • each carbon fiber pultruded body includes one or more carbon fiber pultruded plates, the carbon fiber pultruded plates are stacked along the thickness direction of the carbon fiber pultruded body, wherein the carbon fiber pultruded plates are used
  • the first filling material is solidified
  • One or more inlays which are arranged adjacent to the carbon fiber pultruded body in a direction perpendicular to the thickness direction of the main beam;
  • One or more covering layers covering both sides of the main beam in the thickness direction of the carbon fiber pultruded body and/or inlay;
  • the second pouring material infiltrates the carbon fiber pultruded body, the inlay and the covering layer.
  • the term “main beam” refers to a long and narrow structure used to reinforce the blade on both sides of the blade. Usually, the main beams on both sides are connected with the webs located inside the blade to support the internal space of the blade.
  • the term “inlay” refers to a structure with a certain shape embedded in the main beam.
  • Carbon fiber pultruded plate refers to a material made of carbon fiber infiltrated with a pouring material
  • carbon fiber pultruded body refers to a composite body composed of a plurality of carbon fiber pultruded plates and a pouring material between them.
  • the inlay, the carbon fiber pultruded body and the covering layer in the main beam form a continuous main beam surface, and if necessary, the main beam surface has a desired curvature.
  • the term "infiltration” means that the potting material is poured into the potting object and at least partially combined with it and finally solidified.
  • the glass fiber pouring material between the carbon fiber pultruded plates can be the second pouring material, that is, the pouring of the carbon fiber pultruded plates can be the same process as the second pouring material, which can save the process.
  • the glass fiber pouring material between the carbon fiber pultruded plates can also be different from the second pouring material, and it can be poured in a different process from the second pouring material.
  • the carbon fiber pultruded board and the inlay may be arranged adjacent to each other in a direction perpendicular to the thickness of the main beam, such as in the length and width directions of the main beam, to form the coverage area of the main beam.
  • the carbon fiber pultruded board and the inlay have a strip structure
  • the carbon fiber pultruded board and the inlay can be arranged adjacent to each other in the chord direction of the main beam.
  • chord direction refers to a direction perpendicular to the thickness of the main beam and perpendicular to the length direction of the blade.
  • the one or more carbon fiber pultruded plates include a plurality of carbon fiber pultruded plates, and are arranged between at least two carbon fiber pultruded plates of the plurality of carbon fiber pultruded plates There are glass fiber infusion materials.
  • the carbon fiber pultruded body has m carbon fiber pultruded plates
  • the main beam has n carbon fiber pultruded bodies, p inlays, and q covering layers, wherein m, n, p, and q are all integers ranging from 1 to 100.
  • one or more inlays may be respectively arranged on one side or both sides of each carbon fiber pultruded body. Not only the number of inlays can be adjusted, but the rigidity and flexibility of the inlays are also adjustable, so as to achieve the desired conformability after the second infusion together with the carbon fiber pultruded body, so as to better form the desired curved surface.
  • the first potting material includes one or more of the following: containing thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenol resin, and thermoplastic resin.
  • thermosetting epoxy resin vinyl resin
  • unsaturated polyester resin unsaturated polyester resin
  • thermoplastic resin thermoplastic resin
  • thermoplastic resin includes one or more of the following: polypropylene resin, polyethylene resin, polyvinyl chloride resin, polystyrene resin, polyacrylonitrile-butadiene- Styrene resin, polyamide resin, polyether ether ketone resin, and polyphenylene sulfide resin.
  • polypropylene resin polyethylene resin
  • polyvinyl chloride resin polystyrene resin
  • polyacrylonitrile-butadiene- Styrene resin polyamide resin
  • polyether ether ketone resin polyphenylene sulfide resin
  • the covering layer includes glass fiber fabric or glass fiber non-woven fabric.
  • the inlay includes one or more of the following: PVC foam, PET foam, PMI foam, wood, honeycomb sandwich material, glass fiber pultruded board, glass fiber fabric , Glass fiber non-woven fabric, and glass fiber yarn.
  • PVC foam PET foam
  • PMI foam wood
  • honeycomb sandwich material glass fiber pultruded board
  • glass fiber fabric glass fiber non-woven fabric
  • glass fiber yarn glass fiber yarn
  • the second potting material includes one or more of the following: thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenol resin, and thermoplastic resin.
  • thermoplastic resin includes one or more of the following: polypropylene resin, polyethylene resin, polyvinyl chloride resin, polystyrene resin, polyacrylonitrile-butadiene resin Ethylene-styrene resin, polyamide resin, polyether ether ketone resin, and polyphenylene sulfide resin.
  • the inlay includes:
  • the main body of the inlay the thickness d1 of which is less than or equal to the sum of the thickness D of the adjacent carbon fiber pultruded body and the covering layer;
  • the thickness d2 of the inlay transition part varies between zero and D-d1, wherein the inlay transition part is arranged between the inlay body and the adjacent carbon fiber pultruded body to form a thickness transition.
  • the covering layer only needs to cover the carbon fiber pultruded body.
  • the thickness direction provides more mobility; secondly, since the inlay is composed of the inlay body and the transition part of the inlay in the thickness direction of the main beam, it is perpendicular to the thickness direction of the main beam, such as the chord direction.
  • the above provides more mobility; these mobility are beneficial for the main beam material to form a desired surface shape, such as a curved surface, before pouring, so that it can be cured to maintain the surface shape after pouring.
  • the cross section of the main body of the inlay is rectangular, and the cross section of the transition part of the inlay is triangular.
  • different shapes of the inlay body and the inlay transition part can be adopted.
  • the shape of the inlay body and the transition part of the inlay can be determined according to the desired final shape of the main beam.
  • the aforementioned task is solved by a method for manufacturing a main beam for a wind turbine blade, the method including the following steps:
  • each carbon fiber pultruded body includes one or more carbon fiber pultruded plates, the carbon fiber pultruded plates are stacked in the thickness direction, wherein the carbon fiber pultruded plates use the first pouring material It is cured, in which a glass fiber pouring material is arranged between every two carbon fiber pultruded plates;
  • One or more inlays are arranged adjacent to the carbon fiber pultruded body in a direction perpendicular to the thickness direction of the main beam of the main beam;
  • the carbon fiber pultruded body, the inlay and the covering layer are infiltrated with a second potting material.
  • arranging one or more inlays adjacent to the carbon fiber pultruded body in a direction perpendicular to the thickness direction of the main beam of the main beam includes the following steps:
  • the inlay transition portion is arranged on the inlay body and the adjacent carbon fiber pultruded body to form a thickness transition inlay transition portion, wherein the thickness d2 of the inlay transition portion varies between zero and D-d1.
  • the covering layer only needs to cover the carbon fiber pultruded body.
  • the thickness direction provides more mobility; secondly, since the inlay is composed of multiple parts of the inlay body and the transition part of the inlay in the thickness direction of the main beam, so in the direction perpendicular to the thickness direction of the main beam, such as the chord direction Provides more mobility in the direction; these mobility are beneficial for the main beam material to form a desired surface shape, such as a curved surface, before pouring, and curing to maintain the surface shape after pouring.
  • arranging one or more inlays adjacent to the carbon fiber pultruded body in a direction perpendicular to the thickness direction of the main beam of the main beam includes the following steps:
  • Inlays are arranged on one or both sides of each carbon fiber pultruded body to form a continuous composite body.
  • providing one or more carbon fiber pultruded bodies includes the following steps:
  • a glass fiber infusion layer is arranged between every two carbon fiber pultruded plates for secondary infusion.
  • the present invention has at least the following beneficial effects: (1) The present invention better solves the problems of bubbles and wrinkles in the carbon fiber mixed material through two infusions, that is, the infusion of the carbon fiber pultruded body and the infusion of the main beam.
  • the carbon fiber pultruded body is first infused and solidified, and the second infusion is mainly for the second infusion of the cured carbon fiber pultruded body and the inlay.
  • Carbon-glass mixing can be carried out at the scale of the blade structure design, without being restricted by the material supplier, and the mixing ratio and form can be freely adjusted with different blade models, and the carbon fiber adopts tensile Extrusion process, and the glass fiber can be in the form of glass fiber cloth, for example, through the secondary infusion and solidified together, to ensure that the carbon fiber is used in the form of pultrusion, thereby improving the performance of the main beam.
  • Figures 1A to 1D show a number of embodiments of the main beam according to the present invention
  • Figure 2 shows a schematic diagram of a fan using the main beam according to the present invention.
  • Fig. 3 shows a process flow of a method for manufacturing a main beam for a wind turbine blade according to the present invention.
  • the quantifiers "one” and “one” do not exclude the scenario of multiple elements.
  • the number of the steps of each method of the present invention does not limit the execution order of the method steps. Unless otherwise specified, the method steps can be performed in a different order.
  • Fig. 1A shows a first embodiment according to the present invention.
  • the main beam 100 includes the following components:
  • the second potting material 101b is, for example, a glass fiber fabric or a non-woven fabric.
  • the glass fiber pouring material between the carbon fiber pultruded plates 101a is the second pouring material 101b, that is, the pouring of the carbon fiber pultruded plates 101a is the same process as the second pouring material, which can save Process.
  • the glass fiber pouring material between the carbon fiber pultruded plates 101a may also be different from the second pouring material 101b, and it may be poured in a different process from the second pouring material.
  • the carbon fiber pultruded board 101a is, for example, a certain amount of carbon fiber that is solidified and molded using a first potting material (not shown).
  • the first potting material of the carbon fiber pultruded board 101b may include, for example, one or more of the following: containing thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenol resin, and thermoplastic resin.
  • the thermoplastic resin may include, for example, one or more of the following: polypropylene resin, polyethylene resin, polyvinyl chloride resin, polystyrene resin, polyacrylonitrile-butadiene-styrene resin, polyamide resin, poly Ether ether ketone resin, and polyphenylene sulfide resin.
  • the inlay 102 is arranged adjacent to the carbon fiber pultruded body 101 in a direction perpendicular to the thickness direction of the main beam 100, such as the chord direction B of the main beam 100.
  • chord direction refers to a direction perpendicular to the thickness of the main beam and perpendicular to the length direction of the blade.
  • the inlay 102 is arranged between and flush with the two carbon fiber pultruded bodies 12.
  • the inlay 102 may have a thickness difference with the carbon fiber pultruded body 12, and the thickness difference may be compensated by the inlay transition part or the covering body.
  • the inlay 102 may include, for example, one or more of the following: PVC foam, PET foam, PMI foam, wood, honeycomb sandwich material, glass fiber pultruded board, glass fiber fabric, glass fiber non-woven fabric, and glass fiber yarn.
  • the material, rigidity, flexibility, shape and other parameters of the inlay 102 can be adjusted according to specific applications, so that various physical and dimensional characteristics of the main beam, such as rigidity, thickness, and width, can be easily and accurately adjusted.
  • the covering layer 103 covers the carbon fiber pultruded body and/or the inlay on both sides in the thickness direction A of the main beam 100.
  • the covering layer 103 may include, for example, a glass fiber fabric or a glass fiber non-woven fabric.
  • the covering layer 103 is used, for example, to form the surface of a fan blade, and to protect the internal material from the external environment.
  • two covering layers 103 are shown, which respectively cover both the carbon fiber pultruded body 101 and the inlay 102 on both sides in the thickness direction A of the main beam 100. In other embodiments, the covering layer 103 may only cover the carbon fiber pultruded body 101.
  • the second pouring material 101b infiltrates the carbon fiber pultruded body, the inlay and the covering layer.
  • the second potting material may include, for example, one or more of the following: thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenol resin, and thermoplastic resin.
  • the thermoplastic resin may include, for example, one or more of the following: polypropylene resin, polyethylene resin, polyvinyl chloride resin, polystyrene resin, polyacrylonitrile-butadiene-styrene resin, polyamide resin , Polyether ether ketone resin, and polyphenylene sulfide resin.
  • the main beam 100 By selecting the material and properties of the inlay 102, the compliance of the main beam 100 can be improved while maintaining the rigidity of the main beam 100, and defects such as bubbles and wrinkles in the main beam 100 can be basically avoided. Therefore, the main beam 100 according to the present invention has a large technical improvement compared with the traditional main beam.
  • Fig. 1B shows a second embodiment according to the present invention.
  • each inlay 102 has a smaller width compared to the first embodiment, thereby providing greater rigidity and better compliance.
  • more inlays 102 with a smaller width may be arranged, thereby providing greater rigidity and better compliance.
  • Fig. 1C shows a third embodiment according to the present invention.
  • the inlay 102 includes:
  • the thickness d1 of the inlay body 102a is smaller than the sum D of the thickness of the adjacent carbon fiber pultruded body 101 and the cover layer 102.
  • the cross section of the inlay body 102a may be rectangular, for example.
  • the inlay transition portion 102b the thickness d2 of which varies between zero and D-d1, wherein the inlay transition portion is arranged on the inlay body and the adjacent carbon fiber pultruded body to form a thickness transition.
  • the cross section of the inlay transition part 102b is, for example, a triangle.
  • the inlay body 102a and the inlay transition portion 102b By providing the inlay body 102a and the inlay transition portion 102b, better compliance of the main beam can be achieved.
  • the covering layer 103 only needs to The carbon fiber pultruded body 101 is covered to provide more mobility in the thickness direction A of the main beam 100;
  • the inlay 102 is composed of a plurality of inlay main bodies 102a and inlay transition parts 102b in the thickness direction of the main beam 100 Partial structure, therefore, in the direction perpendicular to the thickness direction of the main beam, such as the chord direction B of the main beam 100, provides more mobility; these mobility are conducive to the formation of the desired surface shape of the main beam material before pouring , Like a curved surface, so it can maintain the surface shape after curing after pouring.
  • Fig. 1D shows a fourth embodiment according to the present invention.
  • the difference between the fourth embodiment and the third embodiment is that the inlay body 102a and the inlay transition portion 102b are arranged on both sides of the carbon fiber pultruded body 101 to form a symmetrical shape transition.
  • This symmetrical shape transition is conducive to forming a thickened part of the main beam material, and the thickened part is conducive to forming a special curved surface of the main beam or compensating for weak parts of the material.
  • Fig. 2 shows a schematic diagram of a wind turbine blade 200 using the main beam 100 according to the present invention.
  • the blade 200 has a blade leading edge 206 and a blade trailing edge 203.
  • the part of the blade 200 before the blade leading edge 206 and the blade trailing edge 203 is divided into a windward surface 201 and a leeward surface 204.
  • the trailing edge beam 202 is arranged close to the trailing edge 203 to improve the strength of the trailing edge.
  • the main beam 100 is respectively arranged on the windward surface 201 and the leeward surface 204, between the leading edge 206 of the blade and the trailing edge 203 of the blade.
  • the main beams 100 are connected by webs 205 to increase the stability of the blades and prevent inward collapse.
  • the rigidity of the blade 200 can be improved, and the compliance of the main beam material can be enhanced, thereby improving the aerodynamic performance and service life of the blade.
  • Fig. 3 shows a process flow 300 of a method for manufacturing a main beam for a wind turbine blade according to the present invention.
  • each carbon fiber pultruded body includes a plurality of carbon fiber pultruded plates, the carbon fiber pultruded plates are stacked in the thickness direction, wherein the carbon fiber pultruded plates use the first
  • the infusion material is solidified, in which a glass fiber infusion material is arranged between every two carbon fiber pultruded plates;
  • step 304 one or more inlays are arranged adjacent to the carbon fiber pultruded body in a direction perpendicular to the thickness direction of the main beam;
  • one or more covering layers are arranged on the carbon fiber pultruded body and/or inlay on both sides in the thickness direction of the main beam;
  • step 308 the carbon fiber pultruded body, inlay and cover layer are infiltrated with a second potting material.
  • the present invention has at least the following beneficial effects: (1)
  • the present invention better solves the problems of bubbles and wrinkles in the carbon fiber mixed material through two infusions, that is, the infusion of the carbon fiber pultruded body and the infusion of the main beam.
  • the present invention only the carbon fiber pultruded body is produced by multiple lamination infusion, and the second infusion is mainly for the infused carbon fiber pultruded body and the inlay. This process is not easy to produce bubbles and wrinkles.
  • the present invention can improve the compliance of the main beam by laying the carbon fiber pultruded body and the inlay in contact with each other.
  • the inlay can be easily adjusted, it can be easily and accurately Adjust the various physical and dimensional characteristics of the main beam, such as rigidity, thickness, width, etc.;
  • Carbon-glass mixing can be carried out at the scale of the blade structure design, independent of the material supplier, and can be freely mixed with different blade models Compared with the form, at the same time, the carbon fiber adopts the pultrusion process, and the glass fiber can be in the form of glass fiber cloth, and solidified together through secondary infusion, which ensures that the carbon fiber is used in the form of pultrusion, thereby improving the performance of the main beam.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Sustainable Energy (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Sustainable Development (AREA)
  • General Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Textile Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Wind Motors (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

一种用于风机叶片的主梁（100），包括：一个或多个碳纤拉挤体（101），其中，每个碳纤拉挤体（101）包括一个或多个碳纤拉挤板（101a），该碳纤拉挤板（101a）沿厚度方向叠放，并利用第一灌注材料固化而成，其中在每两个碳纤拉挤板（101a）之间设置有玻纤灌注材料；一个或多个镶嵌物（102），其在与主梁（100）的厚度方向垂直的方向上与碳纤拉挤体（101）相邻布置；一个或多个覆盖层（103），其在主梁（100）的厚度方向上的两侧覆盖碳纤拉挤体（101）和/或镶嵌物（102）；以及第二灌注材料（101b），其浸润碳纤拉挤体（101）、镶嵌物（102）和覆盖层（103）。通过该主梁，可以在降低碳纤维用量的情况下调整叶片的各项性能如刚度，同时提高主梁对曲面模具的服帖性并且减少气泡褶皱等缺陷，从而提高主梁的所需刚度和使用寿命。还披露了一种制造该主梁的方法以及具有该主梁的风力发电机。

Description

用于风机叶片的主梁及其制造方法 技术领域
本发明总的来说涉及风力发电机领域，具体而言，涉及一种用于风机叶片的主梁。此外，本发明还涉及一种用于制造这样的主梁的方法。
背景技术
近年来，随着各国对环境的重视度提高，清洁能源领域在世界范围内呈现出快速发展的趋势。清洁能源作为一种新型能源，与传统化石燃料相比具有分布广泛、可再生、环境污染小等优点。作为清洁能源的最有潜力的代表，风力发电机的应用日益增多，并有望进一步取代传统化石能源。
风力发电机的叶片是风力发电机捕捉风能的重要组件，其中安装在风机轮毂上的叶片在风能驱动下旋转以产生升力，通过机舱内的传动链进一步转化为转矩带动发电机发电。在相同情况下，叶片构成的叶轮越大，则能够捕捉的风能越多，因此风机的叶片有越来越长的趋势。随着叶片越来越长，净空(净空是指，风机叶片的尖端到塔架的距离，是一个重要的安全指标)越来越成为瓶颈，开发新型叶片材料或叶片设计来提高净空已迫在眉睫。叶片主梁作为贡献挥舞刚度约90％的部件，由此基本决定了净空的大小。
碳纤维是一种高模量高强度材料，但同时价格也较高。因此，如何合理地将碳纤维引入叶片中以达到既提高净空的余量、又尽量少地增加叶片成本，是各大风电公司的当前重要研究课题。由于纯碳纤维主梁的成本过高，一次性投入回本时间过长，因此多种混合碳纤材料应运而生。混合碳纤材料是通过将一定量碳纤维加入传统玻纤材料中生成的。混合碳纤材料可尽量平衡性能和成本。
然而，目前的混合碳纤材料主要具有如下局限性：
1.混合碳纤材料的混合方式多是在材料尺度进行的，例如碳纤维和玻璃纤维以纤维束不同比例混杂编织在同一织物层，或一层碳纤维与一层玻璃纤维混杂而成，这样的混杂形式极度缺少设计自由度，纤维混杂的比例完全由材料供应商制约，对于不同型号的叶片，只有固定的混配 比材料可以选用，无法达到针对每一款型号进行定制的需求。
2.碳纤维的最终力学性能受工艺影响很大，因此一个稳定的工艺路线对最终产品的性能稳定性至关重要。碳玻混合材料(即碳纤维和玻璃纤维的混合材料)一般多采用灌注工艺，即碳玻混合织物多层叠加一同灌注，或几层碳纤维几层玻纤布叠加一起灌注。然而，这种材料的灌注工艺容易产生气泡和褶皱等缺陷，对最终性能大打折扣。
目前需要一种至少部分地消除上述局限性的新型风机主梁或主梁材料。
发明内容
本发明的任务是，提供一种用于风机叶片的主梁及其制造方法，通过该主梁和/或该方法，可以在降低碳纤维用量的情况下调整叶片的各项性能、如刚度，同时提高主梁对曲面模具的服帖性(drapability)并且减少气泡褶皱等缺陷，从而提高主梁的所需刚度和使用寿命。
在本发明的第一方面，该任务通过一种用于风机叶片的主梁来解决，该主梁包括：
一个或多个碳纤拉挤体，每个碳纤拉挤体包括一个或多个碳纤拉挤板，所述碳纤拉挤板沿碳纤拉挤体的厚度方向叠放，其中所述碳纤拉挤板利用第一灌注材料固化而成；
一个或多个镶嵌物，其在与主梁的厚度方向垂直的方向上与所述碳纤拉挤体相邻布置；
一个或多个覆盖层，其在主梁的厚度方向上的两侧覆盖碳纤拉挤体和/或镶嵌物；以及
第二灌注材料，其浸润所述碳纤拉挤体、镶嵌物和覆盖层。
在本发明中，术语“主梁”是指叶片两侧用于增强叶片的狭长结构。通常，两侧主梁与位于叶片内部的腹板连接以支撑叶片内部空间。术语“镶嵌物”是指嵌入主梁中的具有一定形状的结构。“碳纤拉挤板”是指碳纤维经灌注材料浸润制成的材料，，而“碳纤拉挤体”是指由多个碳纤拉挤板与其之间的灌注材料构成的复合体。优选地，镶嵌物与主梁中的碳纤拉挤体和覆盖层一起形成连续的主梁表面，必要时所述主梁表面具有所期望的曲率。术语“浸润”是指灌注材料浇注进灌注对象中并与之至少部分地结合并最终固化。另外，碳纤拉挤板之间的玻纤灌注材 料可以是第二灌注材料，也就是说，碳纤拉挤板的灌注可以与第二灌注材料的灌注是相同工序，这样可以节省工序。但是碳纤拉挤板之间的玻纤灌注材料也可以不同于第二灌注材料，并且与第二灌注材料在不同工序中被灌注。碳纤拉挤板和镶嵌物可以在垂直于主梁的厚度的方向上、如在主梁的长度和宽度方向上彼此相邻布置以构成主梁的覆盖面积。在碳纤拉挤板和镶嵌物为条状结构的情况下，碳纤拉挤板和镶嵌物可以在主梁的弦向上彼此相邻布置。在此，术语“弦向”是指垂直于主梁的厚度且垂直于叶片长度方向的方向。
在本发明的一个优选方案中规定，所述一个或多个碳纤拉挤板包括多个碳纤拉挤板，并且在所述多个碳纤拉挤板中的至少两个碳纤拉挤板之间设置有玻纤灌注材料。
在本发明的一个扩展方案中规定，所述碳纤拉挤体具有m个碳纤拉挤板，并且所述主梁具有n个碳纤拉挤体、p个镶嵌物以及q个覆盖层，其中m、n、p、q均为1至100的整数。例如，在每个碳纤拉挤体的一侧或两侧可以分别布置一个或多个镶嵌物。不仅镶嵌物的数目可调节，而且镶嵌物的刚度和挠性也是可调节的，以便与碳纤拉挤体一起在二次灌注以后实现所期望的服帖性，从而更好地形成所期望的曲面。
在本发明的另一扩展方案中规定，第一灌注材料包括下列各项中的一个或多个：含热固性环氧树脂、乙烯基树脂、不饱和聚酯树脂、酚醛树脂、以及热塑性树脂。在本发明的教导下，其它浇注材料也是可设想的。
在本发明的又一扩展方案中规定，热塑性树脂包括下列各项中的一个或多个：聚丙烯树脂、聚乙烯树脂、聚氯乙烯树脂、聚苯乙烯树脂、聚丙烯腈-丁二烯-苯乙烯树脂、聚酰胺树脂、聚醚醚酮树脂、以及聚苯硫醚树脂。在本发明的教导下，其它热塑性树脂也是可设想的。
在本发明的另一扩展方案中规定，所述覆盖层包括玻纤织物或玻纤无纺布。
在本发明的又一扩展方案中规定，所述镶嵌物包括下列各项中的一个或多个：PVC泡沫、PET泡沫、PMI泡沫、木材、蜂窝夹心材料、玻纤拉挤板、玻纤织物、玻纤无纺布、以及玻纤纱。在本发明的教导下，其它镶嵌物的材料也是可设想的。
在本发明的另一扩展方案中规定，第二灌注材料包括下列各项中的 一个或多个：热固性环氧树脂、乙烯基树脂、不饱和聚酯树脂、酚醛树脂、以及热塑性树脂。
在本发明的又一扩展方案中规定，所述热塑性树脂包括下列各项中的一个或多个：聚丙烯树脂、聚乙烯树脂、聚氯乙烯树脂、聚苯乙烯树脂、聚丙烯腈-丁二烯-苯乙烯树脂、聚酰胺树脂、聚醚醚酮树脂、以及聚苯硫醚树脂。
在本发明的一个优选方案中规定，所述镶嵌物包括：
镶嵌物主体，其厚度d1小于等于相邻碳纤拉挤体和覆盖层的厚度之和D；以及
镶嵌物过渡部，其厚度d2在零与D-d1之间变化，其中镶嵌物过渡部布置在镶嵌物主体与相邻碳纤拉挤体以形成厚度过渡。
通过该优选方案，可以实现主梁的更好的服帖性，其原因在于，首先，在镶嵌物上部存在镶嵌物过渡部的情况下，覆盖层仅需覆盖碳纤拉挤体，从而在主梁的厚度方向提供更多的活动性；其次，由于镶嵌物在主梁的厚度方向上由镶嵌物主体和镶嵌物过渡部多个部分构成，因此在主梁的厚度方向垂直的方向、如弦向方向上提供了更多的活动性；这些活动性有利于主梁材料在灌注前形成所期望的表面形状、如曲面，因此可在灌注后固化保持所述表面形状。
在本发明的一个扩展方案中规定，镶嵌物主体的截面为矩形，并且所述镶嵌物过渡部的截面为三角形。根据不同应用场合，可以采取不同形状的镶嵌物主体和镶嵌物过渡部。例如，可以根据主梁的所期望的最终形状来确定镶嵌物主体和镶嵌物过渡部的形状。
在本发明的第二方面，前述任务通过一种用于制造用于风机叶片的主梁的方法来解决，该方法包括下列步骤：
提供一个或多个碳纤拉挤体，每个碳纤拉挤体包括一个或多个碳纤拉挤板，所述碳纤拉挤板沿厚度方向叠放，其中所述碳纤拉挤板利用第一灌注材料固化而成，其中在每两个碳纤拉挤板之间设置有玻纤灌注材料；
将一个或多个镶嵌物在主梁的与主梁的厚度方向垂直的方向上与所述碳纤拉挤体相邻布置；
在主梁的厚度方向上的两侧在碳纤拉挤体和/或镶嵌物上布置一个或多个覆盖层；以及
用第二灌注材料浸润所述碳纤拉挤体、镶嵌物和覆盖层。
在本发明的一个优选方案中规定，将一个或多个镶嵌物在主梁的与主梁的厚度方向垂直的方向上与所述碳纤拉挤体相邻布置包括下列步骤：
将镶嵌物主体与碳纤拉挤体相邻布置，其中所述镶嵌物主体的厚度d1小于等于相邻碳纤拉挤体和覆盖层的厚度之和D；以及
将镶嵌物过渡部布置在镶嵌物主体与相邻碳纤拉挤体以形成厚度过渡镶嵌物过渡部，其中所述镶嵌物过渡部的厚度d2在零与D-d1之间变化。
通过该优选方案，可以实现主梁的更好的服帖性，其原因在于，首先，在镶嵌物上部存在镶嵌物过渡部的情况下，覆盖层仅需覆盖碳纤拉挤体，从而在主梁的厚度方向提供更多的活动性；其次，由于镶嵌物在主梁的厚度方向上由镶嵌物主体和镶嵌物过渡部多个部分构成，因此在与主梁的厚度方向垂直的方向、如弦向方向上提供了更多的活动性；这些活动性有利于主梁材料在灌注前形成所期望的表面形状、如曲面，在灌注后固化保持所述表面形状。
在本发明的一个扩展方案中规定，将一个或多个镶嵌物在主梁的与主梁的厚度方向垂直的方向上与所述碳纤拉挤体相邻布置包括下列步骤：
在每个碳纤拉挤体的一侧或两侧分别布置镶嵌物以形成连续的复合体。
在本发明的另一扩展方案中规定，提供一个或多个碳纤拉挤体包括下列步骤：
将一个或多个碳纤拉挤板沿厚度方向彼此相叠布置，其中所述碳纤拉挤板已经利用第一灌注材料浸润并固化；以及
在每两个碳纤拉挤板之间设置玻纤灌注层以备二次灌注。本发明至少具有如下有益效果：(1)本发明通过两次灌注、即碳纤拉挤体的灌注和主梁的灌注，较好地解决了碳纤混合材料中的气泡和褶皱问题，这是因为在本发明中，碳纤拉挤体是先灌注固化的，而第二次灌注主要是对已固化好的碳纤拉挤体与镶嵌物进行二次灌注，这个过程不容易产生气泡和褶皱，因为在这个过程中，与现有技术中的碳纤板和玻纤层彼此相叠布置的叠层相比，要灌注的层状物明显更少，因为碳纤拉挤体替代 了混杂纤维铺层，由此大大降低了主梁中的气泡、褶皱等缺陷风险；(2)本发明通过将碳纤拉挤体与镶嵌物彼此相接地铺设，可以提高所制成的主梁的服帖性，使其更好地贴合模具，形成所期望的形状、如曲面；(3)由于镶嵌物的材料、刚性、挠性、形状等参数都是可容易调节，由此可以容易且准确地调节主梁的各种物理和尺寸特征、如刚性、厚度、宽度等；(4)碳玻混杂可以在叶片结构设计的尺度进行，不受材料供应商制约，可随不同叶片型号自由调配混合比及形式，同时碳纤维采用拉挤工艺，而玻纤例如可采用玻纤布的形式，通过二次灌注固化在一起，保证了碳纤维是以拉挤形式使用，从而提高主梁性能。
附图说明
下面结合具体实施方式参考附图进一步阐述本发明。
图1A至图1D示出了根据本发明的主梁的多个实施例；
图2示出了采用根据本发明的主梁的风机的示意图；以及
图3示出了根据本发明的用于制造用于风机叶片的主梁的方法流程。
具体实施方式
应当指出，各附图中的各组件可能为了图解说明而被夸大地示出，而不一定是比例正确的。在各附图中，给相同或功能相同的组件配备了相同的附图标记。
在本发明中，除非特别指出，“布置在…上”、“布置在…上方”以及“布置在…之上”并未排除二者之间存在中间物的情况。此外，“布置在…上或上方”仅仅表示两个部件之间的相对位置关系，而在一定情况下、如在颠倒产品方向后，也可以转换为“布置在…下或下方”，反之亦然。
在本发明中，各实施例仅仅旨在说明本发明的方案，而不应被理解为限制性的。
在本发明中，除非特别指出，量词“一个”、“一”并未排除多个元素的场景。
在此还应当指出，在本发明的实施例中，为清楚、简单起见，可能示出了仅仅一部分部件或组件，但是本领域的普通技术人员能够理解， 在本发明的教导下，可根据具体场景需要添加所需的部件或组件。
在此还应当指出，在本发明的范围内，“相同”、“相等”、“等于”等措辞并不意味着二者数值绝对相等，而是允许一定的合理误差，也就是说，所述措辞也涵盖了“基本上相同”、“基本上相等”、“基本上等于”。以此类推，在本发明中，表方向的术语“垂直于”、“平行于”等等同样涵盖了“基本上垂直于”、“基本上平行于”的含义。
另外，本发明的各方法的步骤的编号并未限定所述方法步骤的执行顺序。除非特别指出，各方法步骤可以以不同顺序执行。
下面结合具体实施方式参考附图进一步阐述本发明。
图1A示出了根据本发明的第一实施例。
在第一实施例中，主梁100具有n个碳纤拉挤体101、p个镶嵌物102以及q个覆盖层103，其中n＝2，p＝1，q＝2。应当指出，n、p、q的数目仅仅是示例性的，在其它实施例中，也可以设置不同的n、p、q的值。
具体而言，主梁100包括下列部件：
·碳纤拉挤体11，其具有多个碳纤拉挤板101a以及第二灌注材料101b，其中所述碳纤拉挤板101a在主梁100的厚度方向A上彼此相叠布置并且被第二灌注材料101b间隔。第二灌注材料101b例如是玻璃纤维织物或无纺布。在本实施例中，碳纤拉挤板101a之间的玻纤灌注材料是第二灌注材料101b，也就是说，碳纤拉挤板101a的灌注与第二灌注材料的灌注是相同工序，这样可以节省工序。但是在其它实施例中，碳纤拉挤板101a之间的玻纤灌注材料也可以不同于第二灌注材料101b，并且与第二灌注材料在不同工序中被灌注。在此，碳纤拉挤板101a例如是一定量的碳纤维利用第一灌注材料(未示出)固化成型的。碳纤拉挤板101b的第一灌注材料例如可以包括下列各项中的一个或多个：含热固性环氧树脂、乙烯基树脂、不饱和聚酯树脂、酚醛树脂、以及热塑性树脂。热塑性树脂例如可以包括下列各项中的一个或多个：聚丙烯树脂、聚乙烯树脂、聚氯乙烯树脂、聚苯乙烯树脂、聚丙烯腈-丁二烯-苯乙烯树脂、聚酰胺树脂、聚醚醚酮树脂、以及聚苯硫醚树脂。
·镶嵌物102，其在与主梁100的厚度方向垂直的方向上、如主梁100的弦向方向B上与所述碳纤拉挤体101相邻布置。在此，术语“弦向”是指垂直于主梁的厚度且垂直于叶片长度方向的方向。在此，镶嵌 物102布置在两个碳纤拉挤体12之间并与其平齐。在其它实施例中，镶嵌物102可以与碳纤拉挤体12之间具有厚度差，并且所述厚度差可以通过镶嵌物过渡部或者覆盖体来补偿。镶嵌物102例如可以包括下列各项中的一个或多个：PVC泡沫、PET泡沫、PMI泡沫、木材、蜂窝夹心材料、玻纤拉挤板、玻纤织物、玻纤无纺布、以及玻纤纱。镶嵌物102的材料、刚性、挠性、形状等参数是可以根据具体应用来调节的，由此可以容易且准确地调节主梁的各种物理和尺寸特征、如刚性、厚度、宽度等。
·覆盖层103，其在主梁100的厚度方向A上的两侧覆盖碳纤拉挤体和/或镶嵌物。覆盖层103例如可以包括玻纤织物或玻纤无纺布。覆盖层103例如用于形成风机叶片的表面，并保护内部材料不受外部环境损害。在此，示出了两个覆盖层103，其分别在主梁100的厚度方向A上的两侧覆盖碳纤拉挤体101和镶嵌物102二者。在其它实施例中，覆盖层103也可以仅仅覆盖碳纤拉挤体101。
·第二灌注材料101b，其浸润所述碳纤拉挤体、镶嵌物和覆盖层。第二灌注材料例如可以包括下列各项中的一个或多个：热固性环氧树脂、乙烯基树脂、不饱和聚酯树脂、酚醛树脂、以及热塑性树脂。所述热塑性树脂例如可以包括下列各项中的一个或多个：聚丙烯树脂、聚乙烯树脂、聚氯乙烯树脂、聚苯乙烯树脂、聚丙烯腈-丁二烯-苯乙烯树脂、聚酰胺树脂、聚醚醚酮树脂、以及聚苯硫醚树脂。
通过选择镶嵌物102的材料和属性，可以在保持主梁100的刚度的情况下提高主梁100的服帖性，并且基本避免主梁100中的气泡、褶皱等缺陷。因此，根据本发明的主梁100与传统主梁相比具有较大技术改进。
图1B示出了根据本发明的第二实施例。
在第二实施例中，主梁100具有n叠碳纤拉挤体101、p个镶嵌物102以及q个覆盖层103，其中n＝3，p＝3，q＝2。应当指出，n、p、q的数目仅仅是示例性的，在其它实施例中，也可以设置不同的n、p、q的值。
在第二实施例中，布置有多个镶嵌物102，且每个镶嵌物102具有与第一实施例相比更小的宽度，由此提供更大的刚度和更好的服帖性。在其它实施例中，也可以布置更多个更小宽度的镶嵌物102，由此提供 更大的刚度和更好的服帖性。
图1C示出了根据本发明的第三实施例。
在第三实施例中，所述镶嵌物102包括：
·镶嵌物主体102a，其厚度d1小于相邻碳纤拉挤体101和覆盖层102的厚度之和D。镶嵌物主体102a的截面例如可以为矩形。
·镶嵌物过渡部102b，其厚度d2在零与D-d1之间变化，其中镶嵌物过渡部布置在镶嵌物主体与相邻碳纤拉挤体以形成厚度过渡。镶嵌物过渡部102b的截面例如为三角形。
通过设置镶嵌物主体102a和镶嵌物过渡部102b，可以实现主梁的更好的服帖性，其原因在于，首先，在镶嵌物102上部存在镶嵌物过渡部102a的情况下，覆盖层103仅需覆盖碳纤拉挤体101，从而在主梁100的厚度方向A提供更多的活动性；其次，由于镶嵌物102在主梁100的厚度方向上由镶嵌物主体102a和镶嵌物过渡部102b多个部分构成，因此在与主梁的厚度方向垂直的方向上、如主梁100的弦向方向B提供了更多的活动性；这些活动性有利于主梁材料在灌注前形成所期望的表面形状、如曲面，因此在灌注后固化可保持所述表面形状。
图1D示出了根据本发明的第四实施例。
第四实施例与第三实施例的区别在于，镶嵌物主体102a和镶嵌物过渡部102b布置在碳纤拉挤体101的两侧，以形成对称的形状过渡。这种对称的形状过渡有利于形成主梁材料的加厚部，所述加厚部有利于形成主梁的特殊曲面或者补偿材料薄弱部位。
图2示出了采用根据本发明的主梁100的风力发电机叶片200的示意图。
如图2所示，叶片200具有叶片前缘206和叶片尾缘203，叶片200处于叶片前缘206与叶片尾缘203之前的部分被分为迎风面201和背风面204。尾缘梁202布置在靠近尾缘203处，以提高尾缘强度。主梁100分别布置在迎风面201和背风面204上、叶片前缘206与叶片尾缘203之间。主梁100之间通过腹板205连接，以增加叶片稳定性，防止向内塌陷。通过本发明的主梁100，可以提高叶片200的刚度，并且增强主梁材料的服帖性，从而提高叶片的气动性能和使用寿命。
图3示出了根据本发明的用于制造用于风机叶片的主梁的方法流程300。
在步骤302，提供一个或多个碳纤拉挤体，每个碳纤拉挤体包括多个碳纤拉挤板，所述碳纤拉挤板沿厚度方向叠放，其中所述碳纤拉挤板利用第一灌注材料固化而成，其中在每两个碳纤拉挤板之间设置有玻纤灌注材料；
在步骤304，将一个或多个镶嵌物在与主梁的厚度方向垂直的方向上与所述碳纤拉挤体相邻布置；
在步骤306，在主梁的厚度方向上的两侧在碳纤拉挤体和/或镶嵌物上布置一个或多个覆盖层；以及
在步骤308，用第二灌注材料浸润所述碳纤拉挤体、镶嵌物和覆盖层。
本发明至少具有如下有益效果：(1)本发明通过两次灌注、即碳纤拉挤体的灌注和主梁的灌注，较好地解决了碳纤混合材料中的气泡和褶皱问题，这是因为在本发明中，仅仅碳纤拉挤体是多个叠层灌注生成的，而第二次灌注主要是对已灌注好的碳纤拉挤体与镶嵌物进行二次灌注，这个过程不容易产生气泡和褶皱，因为在这个过程中，与现有技术中的碳纤板和玻纤层彼此相叠布置的叠层相比，要灌注的层状物明显更少，因为碳纤拉挤体替代了大部分的混杂纤维叠层，由此大大降低了主梁中的气泡、褶皱等缺陷风险；(2)本发明通过将碳纤拉挤体与镶嵌物彼此相接地铺设，可以提高所制成的主梁的服帖性，使其更好地贴合模具，形成所期望的形状、如曲面；(3)由于镶嵌物的材料、刚性、挠性、形状等参数都是可容易调节，由此可以容易且准确地调节主梁的各种物理和尺寸特征、如刚性、厚度、宽度等；(4)碳玻混杂可以在叶片结构设计的尺度进行的，不受材料供应商制约，可随不同叶片型号自由调配混合比及形式，同时碳纤维采用拉挤工艺，而玻纤例如可采用玻纤布的形式，通过二次灌注固化在一起，保证了碳纤维是以拉挤形式使用，从而提高主梁性能。
虽然本发明的一些实施方式已经在本申请文件中予以了描述，但是本领域技术人员能够理解，这些实施方式仅仅是作为示例示出的。本领域技术人员在本发明的教导下可以想到众多的变型方案、替代方案和改进方案而不超出本发明的范围。所附权利要求书旨在限定本发明的范围，并藉此涵盖这些权利要求本身及其等同变换的范围内的方法和结构。

Claims (17)

  1. 一种用于风机叶片的主梁，包括：
    一个或多个碳纤拉挤体，每个碳纤拉挤体包括一个或多个碳纤拉挤板，所述碳纤拉挤板沿碳纤拉挤体的厚度方向叠放，其中所述碳纤拉挤板利用第一灌注材料固化而成；
    一个或多个镶嵌物，其在与主梁的厚度方向垂直的方向上与所述碳纤拉挤体相邻布置；
    一个或多个覆盖层，其在主梁的厚度方向上的两侧覆盖碳纤拉挤体和/或镶嵌物；以及
    第二灌注材料，其浸润所述碳纤拉挤体、镶嵌物和覆盖层。
  2. 根据权利要求1所述的主梁，其中所述一个或多个碳纤拉挤板包括多个碳纤拉挤板，并且在所述多个碳纤拉挤板中的至少两个碳纤拉挤板之间设置有玻纤灌注材料。
  3. 根据权利要求2所述的主梁，其中所述玻纤灌注材料和所述第二灌注材料为相同材料。
  4. 根据权利要求1所述的主梁，其中所述碳纤拉挤体具有m个碳纤拉挤板，并且所述主梁具有n个碳纤拉挤体、p个镶嵌物以及q个覆盖层，其中m、n、p、q均为1至100的整数。
  5. 根据权利要求1所述的主梁，其中第一灌注材料包括下列各项中的一个或多个：含热固性环氧树脂、乙烯基树脂、不饱和聚酯树脂、酚醛树脂、以及热塑性树脂。
  6. 根据权利要求5所述的主梁，其中所述热塑性树脂包括下列各项中的一个或多个：聚丙烯树脂、聚乙烯树脂、聚氯乙烯树脂、聚苯乙烯树脂、聚丙烯腈-丁二烯-苯乙烯树脂、聚酰胺树脂、聚醚醚酮树脂、以及聚苯硫醚树脂。
  7. 根据权利要求1所述的主梁，其中所述覆盖层包括玻纤织物或玻纤无纺布。
  8. 根据权利要求1所述的主梁，其中所述镶嵌物包括下列各项中的一个或多个：PVC泡沫、PET泡沫、PMI泡沫、木材、蜂窝夹心材料、玻纤拉挤板、玻纤织物、玻纤无纺布、以及玻纤纱。
  9. 根据权利要求1所述的主梁，其中第二灌注材料包括下列各项中的一个或多个：热固性环氧树脂、乙烯基树脂、不饱和聚酯树脂、酚醛 树脂、以及热塑性树脂。
  10. 根据权利要求9所述的主梁，其中所述热塑性树脂包括下列各项中的一个或多个：聚丙烯树脂、聚乙烯树脂、聚氯乙烯树脂、聚苯乙烯树脂、聚丙烯腈-丁二烯-苯乙烯树脂、聚酰胺树脂、聚醚醚酮树脂、以及聚苯硫醚树脂。
  11. 根据权利要求1所述的主梁，其中所述镶嵌物包括：
    镶嵌物主体，其厚度d1小于等于相邻碳纤拉挤体和覆盖层的厚度之和D；以及
    镶嵌物过渡部，其厚度d2在零与D-d1之间变化，其中镶嵌物过渡部布置在镶嵌物主体与相邻碳纤拉挤体以形成厚度过渡。
  12. 根据权利要求11所述的主梁，其中镶嵌物主体的截面为矩形，并且所述镶嵌物过渡部的截面为三角形。
  13. 一种用于制造用于风机叶片的主梁的方法，包括下列步骤：
    提供一个或多个碳纤拉挤体，每个碳纤拉挤体包括一个或多个碳纤拉挤板，所述碳纤拉挤板沿厚度方向叠放，其中所述碳纤拉挤板利用第一灌注材料固化而成，其中在每两个碳纤拉挤板之间设置有玻纤灌注材料；
    将一个或多个镶嵌物在与主梁的厚度方向垂直的方向上与所述碳纤拉挤体相邻布置；
    在主梁的厚度方向上的两侧在碳纤拉挤体和/或镶嵌物上布置一个或多个覆盖层；以及
    用第二灌注材料浸润所述碳纤拉挤体、镶嵌物和覆盖层。
  14. 根据权利要求13所述的方法，其中将一个或多个镶嵌物在与主梁的厚度方向垂直的方向上与所述碳纤拉挤体相邻布置包括下列步骤：
    将镶嵌物主体与碳纤拉挤体相邻布置，其中所述镶嵌物主体的厚度d1小于相邻碳纤拉挤体和覆盖层的厚度之和D；以及
    将镶嵌物过渡部布置在镶嵌物主体与相邻碳纤拉挤体以形成厚度过渡镶嵌物过渡部，其中所述镶嵌物过渡部的厚度d2在零与D-d1之间变化。
  15. 根据权利要求13或14所述的方法，其中将一个或多个镶嵌物在与主梁的厚度方向垂直的方向上与所述碳纤拉挤体相邻布置包括下列步骤：
    在每个碳纤拉挤体的两侧分别布置镶嵌物以形成连续的复合体。
  16. 根据权利要求12所述的方法，其中提供一个或多个碳纤拉挤体包括下列步骤：
    将一个或多个碳纤拉挤板沿厚度方向彼此相叠布置，其中所述碳纤拉挤板已经利用第一灌注材料浸润并固化；以及
    在每两个碳纤拉挤板之间设置玻纤灌注层以备二次灌注。
  17. 一种风力发电机，其具有根据权利要求1至11之一所述的主梁。
PCT/CN2020/075678 2020-02-18 2020-02-18 用于风机叶片的主梁及其制造方法 Ceased WO2021163875A1 (zh)

Priority Applications (10)

Application Number Priority Date Filing Date Title
US17/795,541 US11905921B2 (en) 2020-02-18 2020-02-18 Main beam for wind turbine blade and manufacturing method thereof
BR112022016449-1A BR112022016449B1 (pt) 2020-02-18 Turbina eólica, viga principal para pá de turbina eólica e método de fabricação da mesma
RS20250924A RS67232B1 (sr) 2020-02-18 2020-02-18 Glavna greda za lopaticu vetroturbine i način njene izrade
AU2020430267A AU2020430267B2 (en) 2020-02-18 2020-02-18 Main beam for fan blade and manufacturing method therefor
EP20919545.2A EP4108908B1 (en) 2020-02-18 2020-02-18 Main beam for wind turbine blade and manufacturing method thereof
PL20919545.2T PL4108908T3 (pl) 2020-02-18 2020-02-18 Belka główna łopaty turbiny wiatrowej i sposób jej wytwarzania
CN202080003501.9A CN113544379A (zh) 2020-02-18 2020-02-18 用于风机叶片的主梁及其制造方法
PCT/CN2020/075678 WO2021163875A1 (zh) 2020-02-18 2020-02-18 用于风机叶片的主梁及其制造方法
ES20919545T ES3040236T3 (en) 2020-02-18 2020-02-18 Main beam for wind turbine blade and manufacturing method thereof
SA522440165A SA522440165B1 (ar) 2020-02-18 2022-08-14 رافدة رئيسية لريشة توربين رياح وطريقة لتصنيعها

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/CN2020/075678 WO2021163875A1 (zh) 2020-02-18 2020-02-18 用于风机叶片的主梁及其制造方法

Publications (1)

Publication Number Publication Date
WO2021163875A1 true WO2021163875A1 (zh) 2021-08-26

Family

ID=77391400

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CN2020/075678 Ceased WO2021163875A1 (zh) 2020-02-18 2020-02-18 用于风机叶片的主梁及其制造方法

Country Status (9)

Country Link
US (1) US11905921B2 (zh)
EP (1) EP4108908B1 (zh)
CN (1) CN113544379A (zh)
AU (1) AU2020430267B2 (zh)
ES (1) ES3040236T3 (zh)
PL (1) PL4108908T3 (zh)
RS (1) RS67232B1 (zh)
SA (1) SA522440165B1 (zh)
WO (1) WO2021163875A1 (zh)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114571749A (zh) * 2022-01-24 2022-06-03 国电联合动力技术有限公司 一种风电叶片的三维增强预制件及其制备方法
CN117382221A (zh) * 2023-10-17 2024-01-12 中材科技(阳江)风电叶片有限公司 一种风电叶片碳拉挤主梁的层间灌注结构和灌注方法

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113738572B (zh) * 2021-10-13 2023-08-08 吉林重通成飞新材料股份公司 一种风电叶片主梁、风电叶片
CN116423871B (zh) * 2023-04-14 2026-04-10 洛阳双瑞风电叶片有限公司 一种风电叶片拉挤主梁一体灌注工艺方法
CN117162561B (zh) * 2023-11-02 2024-03-22 中材科技风电叶片股份有限公司 热塑性复合主梁成型方法及风电叶片主梁
CN120363505B (zh) * 2025-06-23 2025-10-28 内蒙古工业大学 一种三向正交碳玻混杂复合材料结构在风电叶片上的应用

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103817955A (zh) * 2014-02-28 2014-05-28 中材科技风电叶片股份有限公司 一种风电叶片用复合材料主梁帽的制作方法
CN106401865A (zh) * 2015-07-30 2017-02-15 通用电气公司 具有用于平板翼梁缘条的内部支架的转子叶片
US20170082089A1 (en) * 2015-09-23 2017-03-23 General Electric Company Wind turbine rotor blade components formed from pultruded hybrid-resin fiber-reinforced composites
US20180058422A1 (en) * 2016-08-30 2018-03-01 General Electric Company Pre-cured rotor blade components having areas of variable stiffness
CN108284623A (zh) * 2018-01-29 2018-07-17 江苏金风科技有限公司 叶片部件的制造工艺
CN109094075A (zh) * 2017-06-21 2018-12-28 通用电气公司 具有混合翼梁帽的风力涡轮叶片及相关制作方法
CN109098929A (zh) * 2017-06-21 2018-12-28 通用电气公司 具有混合式翼梁帽的风力涡轮叶片及制造的相关联方法

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB201007336D0 (en) * 2010-04-30 2010-06-16 Blade Dynamics Ltd A modular structural composite beam
US20140271217A1 (en) * 2013-03-15 2014-09-18 Modular Wind Energy, Inc. Efficient wind turbine blade design and associated manufacturing methods using rectangular spars and segmented shear web
GB2528850A (en) * 2014-07-31 2016-02-10 Vestas Wind Sys As Improvements relating to reinforcing structures for wind turbine blades
KR101878158B1 (ko) * 2015-09-03 2018-07-13 세키스이가세이힝코교가부시키가이샤 풍차용 블레이드

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103817955A (zh) * 2014-02-28 2014-05-28 中材科技风电叶片股份有限公司 一种风电叶片用复合材料主梁帽的制作方法
CN106401865A (zh) * 2015-07-30 2017-02-15 通用电气公司 具有用于平板翼梁缘条的内部支架的转子叶片
US20170082089A1 (en) * 2015-09-23 2017-03-23 General Electric Company Wind turbine rotor blade components formed from pultruded hybrid-resin fiber-reinforced composites
US20180058422A1 (en) * 2016-08-30 2018-03-01 General Electric Company Pre-cured rotor blade components having areas of variable stiffness
CN109094075A (zh) * 2017-06-21 2018-12-28 通用电气公司 具有混合翼梁帽的风力涡轮叶片及相关制作方法
CN109098929A (zh) * 2017-06-21 2018-12-28 通用电气公司 具有混合式翼梁帽的风力涡轮叶片及制造的相关联方法
CN108284623A (zh) * 2018-01-29 2018-07-17 江苏金风科技有限公司 叶片部件的制造工艺

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP4108908A4 *

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114571749A (zh) * 2022-01-24 2022-06-03 国电联合动力技术有限公司 一种风电叶片的三维增强预制件及其制备方法
CN114571749B (zh) * 2022-01-24 2023-04-25 国电联合动力技术有限公司 一种风电叶片的三维增强预制件及其制备方法
CN117382221A (zh) * 2023-10-17 2024-01-12 中材科技(阳江)风电叶片有限公司 一种风电叶片碳拉挤主梁的层间灌注结构和灌注方法

Also Published As

Publication number Publication date
EP4108908B1 (en) 2025-07-23
US20230074942A1 (en) 2023-03-09
AU2020430267A1 (en) 2022-09-15
BR112022016449A2 (pt) 2022-10-04
AU2020430267B2 (en) 2024-03-14
EP4108908C0 (en) 2025-07-23
ES3040236T3 (en) 2025-10-29
EP4108908A4 (en) 2023-03-29
PL4108908T3 (pl) 2025-10-20
EP4108908A1 (en) 2022-12-28
RS67232B1 (sr) 2025-10-31
US11905921B2 (en) 2024-02-20
SA522440165B1 (ar) 2024-08-15
CN113544379A (zh) 2021-10-22

Similar Documents

Publication Publication Date Title
WO2021163875A1 (zh) 用于风机叶片的主梁及其制造方法
CN111608852B (zh) 一种轻量化风机叶片及其制作方法
US8622709B2 (en) Wind turbine blade and wind power generator using the same
CN114286891B (zh) 用于风机叶片的主梁及其制造方法
CN111587178B (zh) 制造具有打印的网格结构的风力涡轮转子叶片面板的方法
CN205185343U (zh) 一种风力发电机组复合材料风轮叶片的主梁
EP4205958B1 (en) Wind turbine blade having improved trailing edge structure and fabrication method therefor
CN209855954U (zh) 一种具有前缘梁结构的风电叶片
CN115596604B (zh) 一种多腹板结构模块化风电叶片
CN103603777A (zh) 一种分段式风机叶片
CN218660538U (zh) 一种防止兆瓦级风力发电叶片拉挤片材堆叠的工字扣
CN119042074A (zh) 风电叶片结构预制件、风电叶片及结构预制件的设计方法
CN211008948U (zh) 一种风力发电机叶片用的梁帽结构
CN112292256A (zh) 制造用于风力涡轮的转子叶片构件的方法
CN116368295A (zh) 具有增强结构的风力涡轮机叶片
BR112022016449B1 (pt) Turbina eólica, viga principal para pá de turbina eólica e método de fabricação da mesma
US12338787B2 (en) Shear web for a wind turbine blade and method of making same
CN220447251U (zh) 风电用后缘粘接角模具
US20240399678A1 (en) Spar cap for a wind turbine blade
CN117813448A (zh) 用于风力涡轮机叶片的抗剪腹板及其制作方法
EP4634517A1 (en) Family of wind turbine blades
EP4634518A1 (en) Wind turbine blade
Wang et al. Molding Process and Development of Large Carbon Fiber of Fan Blades with Composite Properties of Materials
CN117136210A (zh) 用于复合面板中由回收纤维增强聚合物材料构成的结构片

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 20919545

Country of ref document: EP

Kind code of ref document: A1

WWE Wipo information: entry into national phase

Ref document number: 2020430267

Country of ref document: AU

REG Reference to national code

Ref country code: BR

Ref legal event code: B01A

Ref document number: 112022016449

Country of ref document: BR

WWE Wipo information: entry into national phase

Ref document number: 202217051864

Country of ref document: IN

ENP Entry into the national phase

Ref document number: 2020430267

Country of ref document: AU

Date of ref document: 20200218

Kind code of ref document: A

NENP Non-entry into the national phase

Ref country code: DE

ENP Entry into the national phase

Ref document number: 2020919545

Country of ref document: EP

Effective date: 20220919

ENP Entry into the national phase

Ref document number: 112022016449

Country of ref document: BR

Kind code of ref document: A2

Effective date: 20220818

WWE Wipo information: entry into national phase

Ref document number: 522440165

Country of ref document: SA

WWE Wipo information: entry into national phase

Ref document number: 522440165

Country of ref document: SA

WWG Wipo information: grant in national office

Ref document number: 522440165

Country of ref document: SA

WWG Wipo information: grant in national office

Ref document number: 2020919545

Country of ref document: EP