CN100560342C - 转子叶片、其制造方法以及具有该转子叶片的风力设备 - Google Patents
转子叶片、其制造方法以及具有该转子叶片的风力设备 Download PDFInfo
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Abstract
本发明涉及一种具有如权利要求1前序部分的特征的支承结构(14)。本发明还涉及一种纤维复合结构的成形体尤其是转子叶片的制造过程，其包括以下步骤：制造形成成形体的外部轮廓的壳体(11，12)；制造由预定长度的纤维束构成的支承结构，所述纤维束浸渍有硬化复合材料，以及将支承结构引入到壳体内。将由强化复合纤维制成的预制复合部件(24)结合到支承结构中。本发明的目的是以上述方式进一步提出的一种方法，从而限制了放热反应并且减小了出现波纹的风险。
Description
技术领域
本发明涉及一种支承结构。本发明进一步涉及一种制造纤维复合结构的成形体，尤其是转子叶片的过程，其包括以下步骤：
-制造形成该成形体的外部轮廓的壳体，
-制造预定长度的纤维束的支承结构，该纤维束浸渍有硬化复合材料，及
-将支承结构引入到壳体内。
本发明进一步涉及一种根据该过程而制造出的转子叶片以及一种具有这样一种转子叶片的风力设备。
背景技术
这种过程在风力设备领域中早已是公知的，使得可以在使用相同的材料的情况下，制造出在支承结构与形成转子叶片外壳的壳体之间具有可靠结合的转子叶片。
在这方面，制造诸如纤维复合材料的半壳体部，该纤维复合材料例如可以是玻璃纤维和环氧树脂，这些半壳体部确定了转子叶片的外部形状。由于这些转子叶片恰好达到大于50米的长度，产生了必须吸收和耗散掉的负载。这是通过设置在转子叶片中的支承结构来实现的。
这样一种公知的支承结构包括所谓的粗纺条(roving web)。这些粗纺条涉及诸如碳纤维或由于低成本而优选地为玻璃纤维的纤维束材料。这些纤维束部分连续地在支承结构或转子叶片的整个长度上延伸。条的数目也随着越来越接近转子叶片根部而增加，以便吸收和耗散由于较大的叶片厚度以及叶片深度而导致的较大负载。
为了实现足够的负载支承能力，使用了适当大数目的粗纺条。该粗纺条在装入预制转子叶片壳体内之前，其浸渍有诸如环氧树脂之类的聚合物。应当理解浸渍操作可通过将聚合物从外面供给的方法进行，同样地也可以通过注射过程来进行。然后将浸渍过的粗纺条装入转子叶片的壳体内的预定位置处。由于转子叶片由相同材料制成，壳体和粗纺条之间的结合极佳。
由于这些粗纺条是“湿”地置入壳体中，然而由于这些湿条不是弯曲刚性的，所以在该过程中易于发生变形。这些变形也称为“波纹”，而在硬化之后导致该位置上的回弹效应。这不利地影响了支承结构或转子叶片的刚度。
另外聚合物的硬化是放热过程，其中热量相应地散发到外部。对于由大量粗纺条构成的支承结构，也需要相应大量的环氧树脂，以便进行适当的结合。放热反应相应增强，并且发出的热量相应较高。
现有技术的大体状况可参照DE 4423115A1以及DE-AS No 1264266。
发明内容
因此本发明的目的是提供一种本说明书开始所提出的那种过程，其可限制放热反应以及降低出现波纹的风险。
根据本发明，通过一种支承结构以及一个制造成形体的过程而实现了该目的。
因此根据本发明，其提出了将预制的弯曲刚性部件结合到支承结构中。就此而言，本发明基于以下实现：纵然预制部件也由例如碳纤维或玻璃纤维条以及聚合物的纤维复合系统制成，预制部件已经硬化，因此允许进行湿处理的材料相应地减少了，因而导致放热反应减少。另外这些预制部件使湿的组成部分硬化，因此导致波纹，即纤维束不需要的变形减少了。
本发明提供一种风力设备的转子叶片，其中该转子叶片是具有纤维复合结构的成形体，并且该转子叶片具有支承结构，该支承结构包括粗纺条，该粗纺条是预定长度的纤维束，所述纤维束设置有硬化复合材料，作为所述支承结构的一部分的所述纤维束在所述支承结构的整个长度上延伸，其特征在于，由纤维束形成的支承结构还包括一体预制的、弯曲刚性的部件，并且所述一体预制的、弯曲刚性的部件包括设置有硬化复合材料的纤维束，所述一体预制的、弯曲刚性的部件在装入所述支承结构内时已处于完全硬化的状态，使得所述一体预制的、弯曲刚性的部件形成防止所述粗纺条变形的支撑结构。优选地，所述纤维束浸渍有该硬化复合材料。
本发明还提供一种风力设备的转子叶片的制造方法，该转子叶片是纤维复合结构的成形体，该方法包括以下步骤：制造形成该成形体外部轮廓的壳体，制造包括粗纺条的支承结构，所述粗纺条是浸渍有硬化复合材料的、预定长度的纤维束，并且将该支承结构引入到所述壳体内，其特征在于，将一体预制的、弯曲刚性的部件结合到所述支承结构中，其中，所述一体预制的、弯曲刚性的部件包括设置有硬化复合材料的纤维束，所述一体预制的、弯曲刚性的部件在装入所述支承结构内时已处于完全硬化的状态，使得所述一体预制的、弯曲刚性的部件形成防止所述粗纺条变形的支撑结构。在一个优选实施方式中，所述一体预制的、弯曲刚性的部件由纤维复合材料制成。
特别地，使用了预定长度的预制部件，其中该长度优选地取决于该部件在该成形体中的安装位置。
更加优选的是，使用在壳体中与负载成适当关系延伸的预制部件。
另外，本发明还提供一种具有上述转子叶片的风力设备。
应理解这些预制部件也可由任何其它适当材料制成。就此而言，使用预制部件的进一步优点在于其可独立制造并易于进行质量控制。
通过该方式确保的这些部件的质量以及较低的放热量，也使得支承结构的质量总体得以提高。
特别地，这些预制部件的长度优选地与欲形成的支承结构的长度大致相等。这实现了同样允许应力连续流动的连续结构。
附图说明
下面参照附图对本发明进行更加详细的描述，附图中：
图1示出了转子叶片的简化截面视图，
图2示出了转子叶片壳体的简化内视图，
图3示出了公知的支承结构的简化视图，
图4示出了根据本发明的支承结构的简化视图，
图5示出了根据本发明的预制部件的放大比例的截面视图，以及
图6示出了根据本发明的支承结构的一个可选实施例。
具体实施方式
参照图1，其中以截面图的形式简化示出的是一种风力设备的转子叶片10。所述转子叶片包括上壳体11和下壳体12。在这些壳体11和12中设置有支承结构14、16，其吸收和耗散作用在转子叶片10上的负载。
图2是所述壳体11、12的简化内视图。壳体11、12的预定位置上设置有支承结构14、16，其在壳体11、12的整个长度上延伸，并在由此形成的转子叶片的整个长度上延伸。
图3再次示出了已知支承结构14、16的简化形式的结构。支承结构由纤维束20——所谓的粗纺条构成，该纤维束由环氧树脂22环绕。应当理解纤维材料可以是碳纤维、玻璃纤维或其它适当的纤维。也应注意该图中所示出的粗纺条的圆形束20仅用于例示目的。事实上该束可以是任何期望的形状。
在该图中可清楚地看到条20和环氧树脂22的这样一种(湿)布置在相当大的长度上易于发生变形——所谓的波纹。
图4示出了根据本发明的支承结构14、16的一个实施例。该支承结构14、16也具有嵌入到环氧树脂22内的粗纺条20。然而应当注意可以清楚地看到插入到根据本发明的支承结构14、16中的预制部件24。预制部件24延伸通过整个长度，并形成可以支承和支撑粗纺条20的层。
由于预制部件24已呈现出其良好的弯曲刚度，其形成了阻止粗纺条20变形的支撑结构。因此，以此构造的支承结构14、16是高质量的。
图5示出了预制部件24的一个实施例的放大比例的截面视图。如从该图中可见，这个预制部件24也是由粗纺条20和环氧树脂22制成的。然而应注意预制部件24在装入支承结构14、16内时其已处于完全硬化的状态，但通过选择其所涉及的材料，可在根据本发明的支承结构14中形成紧密结合，因而确保了令人满意的应力流。
图6示出了根据本发明的支承结构14、16的第二实施例。该情况下，为了简化的目的，该图中未示出预制部件24之间的粗纺条20的布置。从该图中也可看出预制部件24在此处没有以一列在另一列的正下方的方式布置而是各行之间彼此成错位的关系布置。
这种布置导致根据本发明的支承结构14、16甚至具有更好的强度。
由于采用了预制部件，根据本发明的转子叶片具有相当高的稳定性。该情况下，比原先的转子叶片具有更高地吸收张力的能力。
以上借助于作为成形体的可选例子的转子叶片而描述了本发明的结构。除了转子叶片之外，本发明还可极有利地用于机翼、船只或者其它成形体，就这些成形体而言，其需要高强度、高动态负载承受能力。
Claims (7)
1.一种风力设备的转子叶片，其中该转子叶片是具有纤维复合结构的成形体，并且该转子叶片具有支承结构(14，16)，该支承结构(14，16)包括粗纺条(20)，该粗纺条(20)是预定长度的纤维束，所述纤维束设置有硬化复合材料，所述纤维束在所述支承结构(14，16)的整个长度上连续延伸，
其特征在于，由纤维束形成的支承结构(14，16)还包括一体预制的、弯曲刚性的部件(24)，并且所述一体预制的、弯曲刚性的部件(24)包括设置有硬化复合材料的纤维束，所述一体预制的、弯曲刚性的部件(24)在装入所述支承结构(14、16)内时已处于完全硬化的状态，使得所述一体预制的、弯曲刚性的部件(24)形成防止所述粗纺条(20)变形的支撑结构。
2.如权利要求1所述的风力设备的转子叶片，其特征在于，所述纤维束浸渍有该硬化复合材料。
3.一种风力设备的转子叶片的制造方法，该转子叶片是纤维复合结构的成形体，该方法包括以下步骤：
制造形成该成形体外部轮廓的壳体(11，12)，
制造包括粗纺条(20)的支承结构(14，16)，所述粗纺条(20)是浸渍有硬化复合材料的、预定长度的纤维束，并且
将该支承结构(14，16)引入到所述壳体(11，12)内，
其特征在于，将一体预制的、弯曲刚性的部件(24)结合到所述支承结构(14，16)中，
其中，所述一体预制的、弯曲刚性的部件(24)包括设置有硬化复合材料的纤维束，所述一体预制的、弯曲刚性的部件(24)在装入所述支承结构(14、16)内时已处于完全硬化的状态，使得所述一体预制的、弯曲刚性的部件(24)形成防止所述粗纺条(20)变形的支撑结构。
4.如权利要求3所述的方法，其特征在于所述一体预制的、弯曲刚性的部件(24)由纤维复合材料制成。
5.如权利要求3和4中任一项所述的方法，其特征在于，所述一体预制的、弯曲刚性的部件(24)具有预定长度，其中所述长度取决于所述一体预制的、弯曲刚性的部件(24)在该成形体中的安装位置。
6.如权利要求5所述的方法，其特征在于，所述一体预制的、弯曲刚性的部件(24)在所述壳体(11，12)中与负载成适当关系延伸。
7.一种具有如权利要求1或2所述的转子叶片的风力设备。
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE10336461A DE10336461A1 (de) | 2003-08-05 | 2003-08-05 | Verfahren zur Herstellung eines Rotorblattes einer Windenergieanlage |
| DE10336461.7 | 2003-08-05 |
Publications (2)
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| CN1829596A CN1829596A (zh) | 2006-09-06 |
| CN100560342C true CN100560342C (zh) | 2009-11-18 |
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| CNB2004800220504A Expired - Fee Related CN100560342C (zh) | 2003-08-05 | 2004-08-05 | 转子叶片、其制造方法以及具有该转子叶片的风力设备 |
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| US (1) | US7625185B2 (zh) |
| EP (1) | EP1654110B8 (zh) |
| JP (2) | JP4648315B2 (zh) |
| KR (1) | KR100879753B1 (zh) |
| CN (1) | CN100560342C (zh) |
| AR (3) | AR045213A1 (zh) |
| AU (1) | AU2004261415B2 (zh) |
| BR (1) | BRPI0413134B1 (zh) |
| CA (1) | CA2533722C (zh) |
| DE (1) | DE10336461A1 (zh) |
| DK (1) | DK1654110T3 (zh) |
| ES (1) | ES2690301T3 (zh) |
| NZ (1) | NZ545162A (zh) |
| PT (1) | PT1654110T (zh) |
| WO (1) | WO2005011964A1 (zh) |
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2003
- 2003-08-05 DE DE10336461A patent/DE10336461A1/de not_active Withdrawn
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2004
- 2004-08-04 AR ARP040102772A patent/AR045213A1/es not_active Application Discontinuation
- 2004-08-05 CN CNB2004800220504A patent/CN100560342C/zh not_active Expired - Fee Related
- 2004-08-05 KR KR1020067002336A patent/KR100879753B1/ko active IP Right Grant
- 2004-08-05 DK DK04766425.5T patent/DK1654110T3/en active
- 2004-08-05 JP JP2006522360A patent/JP4648315B2/ja not_active Expired - Fee Related
- 2004-08-05 US US10/567,186 patent/US7625185B2/en active Active
- 2004-08-05 BR BRPI0413134A patent/BRPI0413134B1/pt not_active IP Right Cessation
- 2004-08-05 AU AU2004261415A patent/AU2004261415B2/en not_active Ceased
- 2004-08-05 PT PT04766425T patent/PT1654110T/pt unknown
- 2004-08-05 WO PCT/EP2004/051720 patent/WO2005011964A1/de active Application Filing
- 2004-08-05 NZ NZ545162A patent/NZ545162A/en unknown
- 2004-08-05 ES ES04766425.5T patent/ES2690301T3/es not_active Expired - Lifetime
- 2004-08-05 EP EP04766425.5A patent/EP1654110B8/de not_active Revoked
- 2004-08-05 CA CA002533722A patent/CA2533722C/en not_active Expired - Fee Related
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Also Published As
| Publication number | Publication date |
|---|---|
| BRPI0413134A (pt) | 2006-10-03 |
| NZ545162A (en) | 2009-01-31 |
| KR20060037423A (ko) | 2006-05-03 |
| US20070140861A1 (en) | 2007-06-21 |
| DK1654110T3 (en) | 2018-11-19 |
| JP2007533883A (ja) | 2007-11-22 |
| CN1829596A (zh) | 2006-09-06 |
| DE10336461A1 (de) | 2005-03-03 |
| US7625185B2 (en) | 2009-12-01 |
| CA2533722A1 (en) | 2005-02-10 |
| BRPI0413134B1 (pt) | 2016-02-16 |
| JP4648315B2 (ja) | 2011-03-09 |
| EP1654110B8 (de) | 2018-10-17 |
| EP1654110A1 (de) | 2006-05-10 |
| KR100879753B1 (ko) | 2009-01-21 |
| WO2005011964A1 (de) | 2005-02-10 |
| AR074193A2 (es) | 2010-12-29 |
| AU2004261415B2 (en) | 2008-10-30 |
| AR074192A2 (es) | 2010-12-29 |
| JP2010031878A (ja) | 2010-02-12 |
| PT1654110T (pt) | 2018-11-30 |
| AR045213A1 (es) | 2005-10-19 |
| CA2533722C (en) | 2009-01-13 |
| AU2004261415A1 (en) | 2005-02-10 |
| ES2690301T3 (es) | 2018-11-20 |
| EP1654110B1 (de) | 2018-08-29 |
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