CN101084096A - 一种用于风力发电站的纤维加强部件的制造方法 - Google Patents
一种用于风力发电站的纤维加强部件的制造方法 Download PDFInfo
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Abstract
本发明涉及一种用于风力发电站的诸如叶片的纤维加强部件的制造方法,其中,该方法包括在敞口模具的内表面上的薄膜上设置第一最外层;此后在第一层的顶面上设置包括纤维材料层的不同层;并且树脂被用来将设置的层彼此连接。通过对最外层使用薄膜,模塑方法提供工作条件的主要改进。再一个优点还在于,与使用凝胶体涂层相比,表面被实现能更强地抵抗在元件上诸如周期的应力形式的物理影响。本发明还涉及用于风力发电站诸如叶片的纤维加强部件,其中该部件由第一最外层构成,并且还涉及用于风力发电站的叶片以及包括根据本发明的纤维加强部件。
Description
技术领域
本发明涉及一种用于风力发电站的诸如叶片的纤维加强部件的制造方法。本发明还涉及用于风力发电站的诸如叶片的纤维加强部件。最后,本发明涉及用于风力发电站的叶片,该叶片包括纤维加强部件。
背景技术:
在用于风力发电站的诸如叶片的纤维加强部件的制造方法的背景下,典型使用这样的制造方法,其中叶片在它们的每个敞口模具中模塑成两个半部,其中凝胶体涂层最初涂在敞口模具的内表面上。随后设置许多层纤维材料,接着最后使用树脂以将单层纤维材料彼此结合在一起。可通过RTM(树脂传递模塑技术),VARTM(辅助真空树脂传递模塑技术)或其它适合的方法将树脂手动地施加到层上。可选地,在布置层(Prepeg)之前,可将树脂施加到成薄片层上。在该环境中,凝胶体涂层将硬化并形成叶片的表面。
与这种模塑方法相关,使用凝胶体涂层的主要缺点在工作环境方面,即,由于其具有高浓度苯乙烯,以及在该硬化期间放出不合适的气体。所以,通常的情况是与在模具内表面上施加凝胶体涂层有关时使用机器人,从而使员工在施加过程中离开模塑环境以因此使暴露于不良工作条件的员工的危险最小化。但是,通常经常还需要进一步处理,并且对于进一步处理总是要求与凝胶体涂层相对接近接触时有员工在场。
凝胶体涂层的另一个问题是凝胶体涂层是易脆材料并且具有在最后的表面上形成气袋的危险。对于风力涡轮机的叶片,这意味着水可聚集在该袋子内,从而意味着在闪电击中该叶片的情况下叶片被毁掉。
最后,这种凝胶体涂层方法是非常耗时的,随后用于施加凝胶体涂层的设备的清洁也是耗时的。
美国专利申请20040146714传授了诸如船体、澡盆或汽车部件的纤维加强结构的制造方法,其中设置由一层或多层纤维和任意的泡沫部件在远侧接着的薄的热塑性丙烯酸聚合体和热塑性聚合体的复合混合层。具有良好耐磨性和装饰性的最外混合层最初通过热成形方法形成在一个模具内并且然后与纤维层和泡沫部件一起插入第二密封模具,随后模具被密封并注入树脂。但是,由于层内的内部应力和热成形后的收缩,热成形的混合层的尺寸将不可避免地背离固定的模具部件的尺寸。这就带来与RTM方法相关的困难,其中不同层之间的连接强度减小,并且同样地,抛光元件的表面抛光在模具封闭时被刮伤。
发明内容:
因此,本发明的目的在于提供上述问题的解决方法。
这通过用于风力发电站的诸如叶片的纤维加强部件的制造方法实现,其中该方法包括设置不同的层,这些层包括敞口模具的内表面上的多层纤维材料;最后树脂被用于设置的层之间的相互粘合。敞口模具的内表面的最外面设置几层薄膜。当薄膜用作最外层时,模塑方法将提供工作条件的改进。再一个优点是,与使用凝胶体涂层相比,该表面更能抵抗元件上的诸如循环压力形式的物理冲击。而且,由于薄膜的这种层是有利的并且比应用凝胶体涂层快速得多,制造方法相对快速地完成。诸如,薄膜可包括热塑性或热硬化塑性材料,并且根据一个实施例,该薄膜可包括纤维加强部件。在敞口模具的内表面上布置几层薄膜导致元件表面的强度增强,不仅由于组合的最外层的厚度增加,而且由于该层由几层薄膜构成,所以该表面磨损更加缓慢。与在元件上完成的强度增强的表面比较,该表面诸如涂五次一薄层而不是一次涂具有五倍该厚度的一层。该元件被制成在远侧具有几层薄膜,可选择该元件被磨损并且因此一层薄膜被完全或部分磨损而无需确保这种元件的结构特性的结果。相应地,诸如当按预期这样做时,由于抛光或作用消失,根据本发明的方法能去除抛光的元件上的薄膜层。而且在最外层变脏的情况下,为了获得清洁表面并且因此排除清洁表面的需要,选择去掉该层。
根据一个实施例,至少一层薄膜由热塑性材料构成。尤其使用热塑性薄膜,实现这样的表面,即更能抵抗元件的诸如循环应力形式的物理影响或磨损。
根据一个实施例,通过在内表面和该薄膜之间提供的真空使至少一层薄膜适合于敞口模具的内表面的形状。这是特别简单的方式,其中薄膜可适合于敞口模具的内表面的形状。诸如,空气孔可设置在敞口模具的内表面,并且通过将空气从中吸出,薄膜附着在内表面并且因此适合于内表面的形状。
根据一个实施例,通过该薄膜被加热,至少一层薄膜进一步适合于敞口模具的内表面的形状。从而当薄膜布置在内表面上时,褶皱被最小化,并且因此确保完全平滑的薄膜层处于敞口模具的内表面上。
根据一个实施例,通过使用诸如IR(红外)辐射的发热辐射进行加热。从而在薄膜被设置在敞口模具上之后使用外部方法来加热该薄膜,并且热量可按薄膜的不同区域的需要局部调整。当使用IR光时,采用富含能量的辐射。
根据本发明的一个实施例,具有不同特性的薄膜被用在敞口模具的内表面的不同区域上。薄膜可拥有不同的特性,诸如防冰和防污、抛光、空气动力优化和商业化;并且通过在元件上的不同区域设置具有不同特性的薄膜,元件由此具有表面特性变化的表面。诸如,在某些地方希望防冰的表面,这些地方完全暴露冻结成冰;但是其它地方希望空气动力学薄膜,该薄膜提供额外保护免受极度物理影响。
还根据一个实施例,在去掉模具之后,至少一层薄膜设置在纤维加强元件的至少一部分上。因此实现纤维加强元件在其它位置处设有额外薄膜表面,诸如在期望的薄膜的完全暴露在磨损或其它作用的位置。诸如通过这种方式,抛光的叶片顶端等以这样的方式可迅速地给予叶片。同样,该方法能以简单的方式布置另一层薄膜作为元件的部分抛光,诸如横跨连接处。
而且,本发明涉及用于风力发电站的诸如叶片的纤维加强部件的制造方法,其中,该部件由第一最外层和与第一最外层接着的纤维加强材料层构成,纤维加强材料层通过使用树脂而彼此结合,并且第一最外层包括几层薄膜。当使用薄膜作为最外层时,实现提供工作条件主要改进的模塑方法。此处提供再一个优点,与使用凝胶体涂层相比,该表面被实现增强了对在元件上的诸如循环压力形式的物理冲击的抵抗。通过使第一远端层包括几层薄膜,当抛光或作用消失时,实现去除一层或多层薄膜层,或如前所述,该第一远端层可被磨损掉而元件的结构特性没有恶化。而且,最外层变脏的情况下,为了从而提供清洁的表面并且因此排除清洁表面的需要,选择去掉该层。
根据一个实施例,第一最外层包括几层薄膜,其中不同特性的薄膜设置在纤维加强部件的不同区域。薄膜可拥有不同的特性,诸如防冰和防污、抛光、空气动力学优化、商业化;并且通过在元件上的不同区域设置具有不同特性的薄膜,实现该元件具有表面特性变化的表面。诸如,存在期望具有防冰表面的位置,诸如在正好暴露于结冰的区域。但是在其它地方处期望空气动力学薄膜,该薄膜提供额外保护免受极度物理影响。
根据一个实施例,薄膜层包括具有防冰表面的薄膜。因此防止冰停留在元件上,并且当元件是诸如风力涡轮机时避免冰停留在叶片上,冰将明显地恶化叶片的空气动力学特性。而且还会引起转子的不平衡,这可能意味着风力涡轮机停止或在最坏的情况下破裂。
根据一个实施例,薄膜层包括具有空气动力学优化表面的薄膜层。在诸如纤维加强元件上使用这种薄膜可带来风力发电站的性能提高,该纤维加强元件为风力发电站的风力涡轮机的叶片的形式。
最终,本发明涉及用于风力发电站的叶片,其特征在于包括如上所述的纤维加强部件。
附图说明:
在下面,参考附图将进一步详细描述本发明,附图示出本发明的典型实施例:
图1示出敞口模具的一部分,该敞口模具用于模塑具有薄膜作为其外层的叶片外壳。
图2是该敞口模具的剖视图,其中该薄膜适合于该模具的内表面。
图3是该敞口模具的剖视图,其中几个薄膜层设置在该模具的内表面上。
图4是该敞口模具的剖视图,其中不同的薄膜设置在该模具的内表面上的不同位置。
图5是根据本发明的纤维加强元件的剖视图。
图6示出纤维加强元件,其为用于风力发电站的叶片的形式,其中最外层由设置在叶片上的不同位置上的不同类型的薄膜构成。
具体实施方式:
图1示出敞口模具101的局部视图,该敞口模具可用于纤维加强部件的制造,其中该部件的最外层是薄膜。该模具的内表面103包括许多真空孔105和边缘107。使用该敞口模具,因为薄膜的层(优选热塑性薄膜)设置在该模具的内表面103上;该薄膜适合于该敞口模具的内表面的形状,因为在该模具和该薄膜之间设置真空。通过从该真空孔中吸出空气实现该真空,并且在该情况下,该薄膜可最初附着或固定在边缘107以提高真空作用。接着设置多层纤维材料,接着最后添加树脂以使单个层纤维材料彼此粘合,并且当制备树脂时,形成纤维加强部分,在那里该薄膜包括最外层。为节约模具,在设置薄膜之前,可选择在内表面上涂蜡以减少模具上的磨损。纤维加强部件的一个例子可以用于风力发电站的部件,诸如叶片、塔台或者发动机罩。
根据一个实施例,当元件通过粘接与其它元件连接时,真空孔用于通过真空的方式固定该元件。诸如在连接两个叶片外壳中。在该连接中,该孔可被用来通过空气压力的方法从模具中喷出该元件。
图2是敞口模具101的剖视图,其说明了热塑性薄膜怎样适合于敞口模具101的内表面103。在薄膜201和内表面103之间提供真空,由此薄膜201被向下吸向内表面103上。在所示的例子中,还设置光源203用于发射热光线,该热光线用作加热薄膜的目的,由此薄膜被软化并因此在该敞口模具的内表面上形成更平滑的表面。用于加热薄膜,可选择使用诸如红外(IR)光源或紫外(UV)光源。
诸如,热塑性薄膜可以是具有厚度在从0.05mm到0.7mm的区间内的PMMA。可采用的其它热塑性薄膜的例子可以是ABS塑料、聚乙烯、聚丙烯或所述塑料类型的混合。
根据一个实施例,薄膜可以通过使用带诸如粘胶带附着在该模具的边缘。可选地,该薄膜可通过使用机械锁诸如安置在边缘上的框架来固定,并且该薄膜位于该框架和该敞口模具的边缘之间。该薄膜还可借助于衬垫或真空凹槽固定在边缘上。
图3是敞口模具101的剖视图,其中几层薄膜301,303,305,307一个在另一个上地设置在模具101的内表面103的顶部上。在薄膜被设置之后,设置多个层纤维材料,随后树脂被最后应用以使单层纤维材料彼此结合,并且当树脂被硬化时形成纤维加强部分,在那里几层薄膜构成远端层。从而在薄膜的抛光或作用消失时,可去除该薄膜层。
单层薄膜可在其通过旋转设置在该敞口模具中之前被彼此粘接;可选地,可利用合适胶将它们粘合而结合在一起。
图4是敞口模具101的剖视图,其中不同薄膜403、405、407被设置在该模具的内表面103上的不同位置。该可以实现,诸如如果希望在将被模塑的纤维加强元件上的不同位置上设置具有不同特性的薄膜。
图5是根据本发明的纤维加强元件501的剖视图。示出的元件由两个组合的纤维加强元件503和505构成,其中最外层元件是薄膜507和509。对应于风力发电站的叶片的构成,支承梁511设置在中空的纤维加强元件501的内部。具有外薄膜层的纤维加强元件503和505可在诸如图1所示的敞口模具内被模塑,此后纤维元件被组合以形成元件501。本发明的一个可能的实施例是,纤维加强部件被模塑,而不具有最远端的薄膜层,并且在模塑过程之后依次添加该薄膜层。可在安装过程,磨削步骤或任何其它类型的进一步加工之前或之后施加一层或多层薄膜,如果有的话。诸如,薄膜层可被施加作为横跨连接处的抛光并且有利于它们的强度。
图6示出采取用于风力发电站的叶片601形式的纤维加强元件,其中最外层由设置在叶片的不同位置603、605、607和609上的不同类型薄膜构成。
应该理解,当被以下权利要求授予的保护范围继续包括时,如在上述描述和附图中公开的本发明可被修改或修正。
Claims (12)
1.一种用于风力发电站的诸如叶片的纤维加强部件的制造方法,其中所述方法包括设置不同的层,这些层包括在敞口模具的内表面上的一层纤维材料;树脂被施加用来连接所述设置的层,其特征在于,在敞口模具的内表面上的最外面设置几层薄膜。
2.根据权利要求1所述的方法,其中至少一层薄膜是由热塑性材料构成的。
3.根据权利要求1-2所述的方法,其中由于在薄膜和内表面之间采用真空,至少一层薄膜适合于敞口模具的内表面的形状。
4.根据权利要求1-3所述的方法,其中由于薄膜被加热,至少一层薄膜适合于敞口模具的内表面的形状。
5.根据权利要求4所述的方法,其中通过使用诸如红外辐射的发热辐射进行加热。
6.根据权利要求1-5所述的方法,其中具有不同特性的薄膜被设置在敞口模具的内表面上的不同位置。
7.根据权利要求1-6所述的方法,进一步包括在去掉模具之后,在所述纤维加强部件的至少一部分上布置至少一个薄膜层。
8.一种用于风力发电站的诸如叶片的纤维加强部件,其中所述部件由第一最外层和与第一最外层接着的一层或多层纤维材料构成,这些层通过使用树脂彼此结合,其特征在于,所述第一最外层包括几层薄膜。
9.根据权利要求8所述的纤维加强部件,其中所述第一最外层由几层薄膜构成,在那里具有不同特性的薄膜被设置在所述纤维加强部件上的不同位置。
10.根据权利要求8-9所述的纤维加强部件,其中所述薄膜层包括具有防冰表面的薄膜。
11.根据权利要求8-10所述的纤维加强部件,其中所述薄膜层包括具有空气动力优化表面的薄膜。
12.一种用于风力发电站的叶片,其特征在于,其包括根据权利要求8-11所述的纤维加强部件。
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CN102027230A (zh) * | 2008-03-28 | 2011-04-20 | 刀具动力学有限公司 | 风力涡轮机叶片 |
CN102439292A (zh) * | 2009-04-20 | 2012-05-02 | 艾劳埃斯·乌本 | 转子叶片、转子叶片元件及制造方法 |
CN102439292B (zh) * | 2009-04-20 | 2015-04-22 | 艾劳埃斯·乌本 | 转子叶片、转子叶片元件及制造方法 |
TWI504646B (zh) * | 2009-04-20 | 2015-10-21 | Wobben Aloys | 轉子葉片,轉子葉片元件及製程 |
CN102459875A (zh) * | 2009-06-30 | 2012-05-16 | 维斯塔斯风力系统集团公司 | 制造包括通过粘结剂结合的两个元件的风力涡轮机叶片的方法 |
CN102459875B (zh) * | 2009-06-30 | 2014-03-05 | 维斯塔斯风力系统集团公司 | 制造包括通过粘结剂结合的两个元件的风力涡轮机叶片的方法 |
CN105073400A (zh) * | 2012-12-21 | 2015-11-18 | 维斯塔斯风力系统有限公司 | 使用预制的增强材料堆叠体来制造风轮机叶片的方法 |
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US20080304971A1 (en) | 2008-12-11 |
DK176418B1 (da) | 2008-01-21 |
WO2006066593A1 (en) | 2006-06-29 |
EP1830992B1 (en) | 2017-02-15 |
PL1830992T3 (pl) | 2017-08-31 |
CN101084096B (zh) | 2010-09-29 |
DK200401988A (da) | 2006-06-23 |
EP1830992A1 (en) | 2007-09-12 |
US8240992B2 (en) | 2012-08-14 |
ES2625349T3 (es) | 2017-07-19 |
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