CN101149041A - 粘结缝形成方法 - Google Patents

粘结缝形成方法 Download PDF

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CN101149041A
CN101149041A CNA2007101529385A CN200710152938A CN101149041A CN 101149041 A CN101149041 A CN 101149041A CN A2007101529385 A CNA2007101529385 A CN A2007101529385A CN 200710152938 A CN200710152938 A CN 200710152938A CN 101149041 A CN101149041 A CN 101149041A
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blade
cavity
blade enclosure
tackiness agent
enclosure
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CN101149041B (zh
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S·范布罗伊格尔
W·巴克惠斯
A·比伦
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LM Wind Power AS
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Abstract

提供了一种在叶片的第一外壳和第二外壳之间的粘结缝形成方法。该方法包括步骤：在所述第一叶片外壳和第二叶片外壳之间形成空腔(1448)以及将粘合剂(500)填充到所述空腔(1448)内用以在所述第一叶片外壳和第二叶片外壳之间形成粘结缝。

Description

粘结缝形成方法
技术领域
本发明涉及在待粘结到一起的两个部件之间形成粘结缝(bondline)，尤其涉及在风力涡轮机转子叶片的两个外壳之间形成粘结缝。
背景技术
近年来作为备用能源的风力已引起大量关注。风力涡轮机用来将动态的风能转变成电能。为此目的，实用类的风力涡轮机具有风力转子，风力转子通常配备三个巨大的转子叶片用以从风中吸收动能。这些转子叶片的典型长度处于10-100米的范围内。转子叶片存在不同的设计但典型地由纤维增强材料制成，如玻璃纤维、碳素纤维、芳香尼龙纤维或其类似物。此外，风力涡轮机转子叶片典型地为组合设计，也就是叶片本体由粘结到一起的两个叶片外壳制造而成。
目前用于将叶片外壳粘结到一起的方法如下所示。将适合的粘合剂施加到一个或两个叶片外壳的表面上，然后将叶片外壳例如通过将外壳彼此紧接着放置而产生接触。因此，用于装配叶片外壳的为不受控力。这种传统的工艺仅仅提供对形成在叶片外壳之间的粘结缝的最小限度的控制。此外，对大量粘合剂的需求增加了转子叶片的成本和重量。
发明内容
鉴于上文所述，提供了一种用于在叶片的第一外壳和第二外壳之间形成粘结的方法。该方法包括步骤：在所述第一叶片外壳和第二叶片外壳之间形成空腔以及将粘合剂填充到所述空腔内用以在所述第一叶片外壳和第二叶片外壳之间形成粘结缝。
通过从属权利要求、说明书并结合附图，可以清楚本发明的另外的方面、优点和特征。
根据本发明的第一个方面，提供了一种用于在叶片的第一半和第二半之间形成粘结缝的方法。该方法包括步骤：在至少第一叶片半内提供长形的凹部；将第二叶片半邻接在所述第一叶片半上，使得通过所述长形的凹部在所述第一叶片半和第二叶片半之间形成空心空间；以及将粘合剂注入或灌输到所述空心空间内用以在所述第一叶片半和第二叶片半之间形成粘结缝。
根据本发明的另外的方面，提供了一种用于在叶片的第一外壳和第二外壳之间形成粘结的方法。该方法包括步骤：在至少第一叶片外壳内形成开槽；在所述开槽内放置可膨胀的粘合剂；将第二叶片外壳放置在所述第一叶片外壳上使得通过所述容纳可膨胀的粘合剂的开槽在所述第一叶片外壳和第二叶片外壳之间形成空腔；以及使得所述可膨胀的粘合剂膨胀用以在所述第一叶片外壳和第二叶片外壳之间形成粘结缝。
根据本发明不同方面的两种方法提供了对在待装配的零件之间形成粘结缝的较好控制。详细地讲，引导粘合剂并将其保持在当装配外壳时所形成的空腔内。此外，空腔的大小和截面形状可鉴于待装配的零件以及在叶片运行期间这些零件上的负荷而预先确定。因此，本发明较好地提供了对粘结缝形成过程的控制。此外，能够降低所使用的粘合剂数量以便节约转子叶片的成本和重量。
根据本发明的另一个方面，提供了用于风力涡轮机转子叶片的外壳。叶片外壳包括形成在粘结缝区的开槽，使得所述开槽由互补的叶片外壳覆盖时形成空腔。
附图说明
对本领域普通技术人员来讲，在说明书的剩余部分包括参照附图，更加详细地阐明了本发明其中包括最佳实施方式的完整且使之能够实现的公开，在附图中：
图1为风力涡轮机的示意图。
图2示出了风力涡轮机的转子叶片。
图3为图2所示的转子叶片沿线A-A的截面图。
图4为根据本发明实施例的转子叶片的叶片外壳的截面图。
图5示出了根据本发明不同实施例的叶片外壳的细节。
图6示出了根据本发明另外不同实施例的叶片外壳的细节。
图7示出了根据本发明另外的实施例的配置的截面图。
图8示出了根据本发明实施例的方法。
图9示出了根据本发明另一实施例的方法。
图10为在本发明实施例中所使用的配置的截面图。
图11示出了本发明又一实施例的方法。
元件符号说明：
100风力涡轮机
110塔架
120舱
130毂
140转子叶片
500粘合剂
510未膨胀的粘合剂
520已膨胀的粘合剂
550紫外光、热等
800注射器
810粘合剂容器
820管口
830泵
900软管
910管口
1410叶片本体
1412第一叶片外壳
1414第二叶片外壳
1420叶片根部
1430叶片顶端
1440前缘
1441壳体
1442接触表面
1443密封件
1444开槽
1445前缘粘结缝
1446注入孔
1447排气孔
1448空腔
1450后缘
1455后缘粘结缝
1460翼梁
1470抗剪腹板
F   力
具体实施方式
现在将详细地参照本发明的各种实施例，在图中举例说明了各种实施例中的一个或多个示例。提供的每个示例作为对本发明的解释，而并不是对本发明的限定。例如，作为一个实施例的部分而举例说明或描述的特征，可以用在或结合其它实施例用以又产生另外的实施例。显然本发明包括这样的修改和变动。
图1为风力涡轮机100的示意图。风力涡轮机100具有塔架110，机器舱120安装在塔架110上。典型地，机器舱容纳发电机、齿轮箱和涡轮机控制装置(未示出)。用于将动态的风能转变成转动能量的风力转子安装到机器舱120的一端。风力转子包括以可转动的方式安装到机器舱120上的毂130，使得毂130能够绕着水平轴线转动。此外，三个转子叶片140安装到毂130上。典型地，转子叶片140可以绕着它们的纵轴线转动以便能够调整转子叶片的倾角。
图2更为详细地示出了风力涡轮机100的转子叶片140。转子叶片140具有叶片本体1410，叶片本体1410在叶片根部1420和顶端1430之间沿着转子叶片140的纵向或者翼展方向延伸。典型地，叶片本体1410由纤维增强材料制成，如玻璃纤维、碳素纤维、芳香尼龙纤维或其类似物。转子叶片140安装到位于叶片根部1420的毂130上。叶片本体还包括前缘1440和后缘1450。如果转子叶片为组合设计，则上方的叶片外壳和下方的叶片外壳如同下文将要解释的那样，典型地沿着叶片的前缘1440和后缘1450连接在一起。
图3为图2所示的转子叶片沿线A-A的截面图。其中，示出了在前缘1440和后缘1450之间沿翼弦方向A-A延伸的叶片本体1410。叶片本体1410由在前缘1440和后缘1450处结合的第一叶片外壳1412和第二叶片外壳1414形成。第一叶片外壳1412和第二叶片外壳1414也可以分别称作第一叶片半和第二叶片半。叶片本体1410的第一半和第二半分别在前缘1440和后缘1450处粘结在一起，以便形成前缘粘结缝1445和后缘粘结缝1455。典型地，粘结缝通过使用适合的粘合剂如聚氨酯(polyurethane)、环氧树脂、乙烯酯类、丙烯酸酯或它们的组合而形成。
此外，在叶片本体1410内设置翼梁1460用以增强叶片本体1410在风力负荷下的抗弯强度和/或抗扭强度。此外，设置抗剪腹板1470用以增强叶片本体1410在风力负荷下的抗剪切强度。典型地但不限于此，翼梁1460和抗剪腹板1470都由纤维增强材料制成，如玻璃纤维、碳素纤维、芳香尼龙纤维或其类似物。此外，翼梁1460和/或抗剪腹板1470可以粘结到叶片外壳1412、1414中的一个或两个上。因此，粘结缝(未示出)必须在翼梁1460和/或抗剪腹板1470和第一叶片外壳1412和第二叶片外壳1414中的至少一个之间形成。当然，本发明能够适用于形成翼梁1460和/或抗剪腹板1470的这些粘结缝。翼梁1460和抗剪腹板1470为风力涡轮机转子叶片任选的但却是典型的特征。然而，应当理解的是，本发明也可以不用通过设置翼梁1460和/或抗剪腹板1470而实施。
图4为根据本发明实施例的转子叶片的叶片外壳的截面图。其中，更为详细地示出了利用本发明的叶片外壳1412的构造。叶片外壳1412的后缘1440的放大图示出了叶片外壳1412具有接触表面1442，接触表面1442构造成同另一叶片半的类似接触表面配合。开槽1444形成在接触表面1442内并沿着希望的待形成的粘结缝方向延伸，例如沿着从根部到顶端的叶片翼展方向。典型地，开槽1444作为具有圆形、半圆形或半椭圆形截面的长形的凹部整体形成。然而，其它的截面形状如多边形或三角形，如果可适用也可以使用。此外，开槽1444的宽度、深度和/或形状在它的整个长度上可以是恒定的，但如果需要也可以变动。类似的后缘开槽1454设置在叶片外壳1412的后缘部分1450上。如图4左侧所示，后缘开槽1454形成在叶片外壳1412的后缘部分1450的接触表面1452上。当然，上文中有关前缘开槽的解释也适用于后缘开槽。
图5示出了根据本发明不同实施例的叶片外壳的细节。在图5的左侧，示出了叶片的前缘部分1440。其中，第一叶片外壳1412和第二叶片外壳1414邻接在它们各自的接触表面上。叶片外壳1412、1414中的每个都在其中形成开槽1444。由于开槽1444相互对准，故它们在叶片的前缘部分1440内形成空腔1448。在图5的右侧示出了一种类似的但有些不同的实施例。其中，仅仅只有第一叶片外壳1412具有在其中形成的开槽1444而第二叶片外壳1414不具有这样的开槽。然而，当第一外壳1412和第二叶片外壳1414覆盖在一起时仍然形成空腔1448。尽管在此未详细示出，但应当理解的是，通过在第一叶片外壳和/或第二叶片外壳内设置至少一个后缘开槽1455可以在叶片140的后缘部分1450上形成类似的空腔。
图6示出了根据本发明另外不同实施例的叶片外壳的细节。图6左侧所示的实施例与图5右侧所示的实施例相似。然而，提供了另外的注入孔1446，其中，注入孔在空腔1448和外部环境之间延伸。在图6所示的实施例中，注入孔1446从空腔1448向叶片外壳1412的外表面延伸。然而，对注入孔1446来讲，从空腔1448向叶片外壳1412的内表面延伸也是可能的。根据另外的构造，注入孔1446可以从空腔1448向第二叶片外壳1414的内表面和/或外表面延伸。当形成粘结缝时，粘合剂将通过注入孔1446注射到空腔1448内。因此，注入孔1446的确切位置和构造将由用于注入粘合剂的注射器决定。例如，注入孔1446的口部可以专门地适于接收注射器的管口。此外，可以设置专门设计的塞子用以在已注入粘合剂后关闭注入孔1446。也应当考虑当位于叶片外壳1412的外表面时通向注入孔1446是较为容易的。然而，叶片的空气动力学特性可能由于注入孔1446而变坏，因此指向叶片外壳1412内表面上注入孔1446的位置作为令人感兴趣的备选方案。
在图6的右侧，示出了根据本发明实施例的另一特征。其中，排气孔1447在空腔1448和叶片外壳1412的内表面之间延伸。当然，排气孔1447可以选择性地或者另外地从空腔1448延伸到叶片外壳1412的外表面。根据又一构造，排气孔1447可以从空腔1448向第二叶片外壳1414的内表面和/或外表面延伸。一个或多个排气孔1447用作在粘结缝形成过程中从空腔1448排出空气或气体。详细地讲，粘合剂在注入到空腔1448时排除容纳在空腔内的空气，而空气通过排气孔1447排出。并且，注入到空腔内的粘合剂可以脱气使得在空腔1448内产生大量的气体。这些气体可以通过排气孔1447排出。典型地，排气孔1447的直径同注入孔1446的直径相比是比较小的，更典型地讲是相当地小。
尽管本发明上述实施例已论述了有关叶片前缘部分1440，但熟练的阅读人员将会容易地理解类似的构造可以应用到形成粘结缝的其它部分。特别是，具有开槽和/或注入孔和/或排气孔的类似构造能够应用到这些如后缘部分、翼梁和/或抗剪腹板的部分。
图7示出了根据本发明另外实施例的配置的截面图。其中，空腔1448不是由位于叶片外壳1412、1414中的一个或两个内的开槽或凹部形成，而是由附着在第一叶片外壳和第二叶片外壳1412、1414内用以形成空腔1448的附加壳体1441形成。在本实施例中，壳体1441的一端由真空紧密封件1443密封。因此，空腔1448适于粘合剂的真空灌输。为此目的，灌输开口1446形成在叶片外壳的外表面上。粘合剂500可以通过真空灌输的方式灌输到空腔1448内。当然，空腔1448也可以通过注入技术充满粘合剂，壳体开口1446在注入技术中用作注入开口。此外，排气孔(未示出)可以设置在叶片外壳1412、1414内，或者如果选用粘合剂注入技术则设置在壳体1441内。
图8示出了根据本发明实施例的方法。在根据本方法的第一步骤(a)中，将可膨胀的粘合剂500放置在开槽1444内，而开槽1444形成在叶片外壳内。接着在步骤(b)中，将第二叶片外壳放置在第一叶片外壳上以便形成空腔1448，而处于未膨胀状态510的可膨胀的粘合剂500容纳在空腔1448中。随后，在步骤(c)中通过应用膨胀方法使得可膨胀的粘合剂500膨胀。例如，可膨胀的粘合剂500可以通过将其曝露于紫外(UV)光和/或使其受热的方式而膨胀。另外地或者备选地，可以在步骤(b)之前或者之后将泡沫剂和/或化学硬化剂施加到粘合剂500内。例如，泡沫剂和/或化学硬化剂可以通过注入孔1446注入到空腔1448内。最后，在步骤(d)，处于膨胀状态520的粘合剂填充空腔1448并在第一叶片外壳和第二叶片外壳1412、1414之间形成明确的粘结缝。典型地，可膨胀的粘合剂选自聚氨酯、环氧树脂、乙烯酯类、丙烯酸酯或它们的组合。然而，与上文所述的那些相比较，也有其它的可膨胀的粘合剂和膨胀方法在本领域内广为所知并且可以在本发明范围内应用。
图9示出了根据本发明另一实施例的方法。在第一步骤(a)中，第一叶片外壳和第二叶片外壳1412、1414以上文所述的方式放置在彼此之上用以形成空腔1448。上文所述构造的注入孔1446设置在第一叶片外壳1412的外表面上。如上文所述，注入孔1446也可以位于叶片外壳1412的内表面上或者第二叶片外壳1414的内表面或者外表面上。接着，在步骤(b)中将注射器800施加到注入孔1446的口部。在本实施例中，注射器800包括容纳大量粘合剂500的粘合剂容器810、适于安装到注入孔1446的管口820以及适于将粘合剂500泵送到空腔1448内的泵830。当然，注射器800在不脱离本发明的范围内也有能够应用的其它合适的构造。将力F施加到泵830上向下挤压活塞(未示出)用以将粘合剂500注入到空腔1448内。最后，在步骤(c)中已注入的粘合剂500填充空腔1448用以在第一叶片外壳和第二叶片外壳1412、1414之间形成明确的粘结缝1445。在注入期间，粘合剂将排出空腔1448内的任何空气或气体。因此，可以设置上文所述构造的排气孔1447。因此，当将粘合剂500注入到空腔1448内时，空腔1448内的空气或气体可以通过排气孔排出。典型地，粘合剂选自聚氨酯、环氧树脂、乙烯酯类、丙烯酸酯或它们的组合。然而，与上文所述的那些相比较，也有其它的粘合剂和注入方法在本领域内广为所知并且可以在本发明范围内应用。
尽管上文描述了粘合剂到空腔1448的注入，但应当理解的是，也有其它的通过粘合剂填充空腔1448的技术能够被采用。特别地，灌输就是这样的一种本领域内广为所知的技术。当采用灌输技术时，对空腔1448抽真空以便将粘合剂吸入到空腔1448内。也就是说，通过对空腔1448抽真空的方式将粘合剂500灌输到空腔1448内。
图10为在本发明实施例中所使用的配置的截面图。其中，具有管口910的软管900设置在空腔1448内而空腔1448形成在第一叶片外壳和第二叶片外壳1412、1414之间。软管900以可收回的方式放置在空腔1448内。例如，在软管900和开槽1444的表面之间设置间隙，也就是说，软管900的截面面积小于空腔1448的截面面积。另外地或者备选地，可以在软管900的外表面上和/或开槽1444、1454的表面上设置润滑剂以便有利于软管900的收回。现在将参照图11解释软管900的使用。
图11示出了本发明又一实施例的方法。其中，在步骤(a)中示出了转子叶片140的平面图。在步骤(a)所述的制造状态中，第一叶片外壳和第二叶片外壳彼此上下放置。此外，软管900放置在由前缘开槽1444形成的空腔1448内。软管900的管口910位于叶片140的顶端部分1430而软管900向下延伸到根部1420。在步骤(b)和步骤(c)中，示出了在粘合剂500通过软管900注入到空腔1448内的同时怎样收回位于空腔1448内的软管900。熟练的阅读人员将会理解软管900的收回速度和粘合剂500的泵送率必须相对于另一个进行调整，使得空腔1448可靠地充满粘合剂500。最后，在步骤(d)中明确的粘结缝1445以受控方式形成在空腔1448内。
尽管本发明上述实施例已论述了有关叶片前缘部分1440，但熟练的阅读人员将会容易地理解类似的构造可以应用到待形成粘结缝的其它部分。特别是，具有开槽和/或注入孔和/或排气孔的类似构造能够应用到这些如后缘部分、翼梁和/或抗剪腹板的部分。
本书面说明采用了示例用以公开包括最佳实施方式的本发明，并且也使得本领域普通技术人员能够制造或使用本发明。当在根据各种特定实施例描述本发明时，本领域普通技术人员将认为本发明能以在权利要求精神和范围内的改动进行实施。特别是，上文所述实施例的互不排斥的特征可以相互结合。本发明的可专利范围由权利要求所限定，并且可以包括本领域普通技术人员所想到的其它示例。这样的其它示例如果没有不同于权利要求书面语言的结构元件、或者包括与权利要求书面语言无实质差别的等同结构元件，认定为落入权利要求范围内。

Claims (10)

1.一种用于在叶片的第一外壳和第二外壳之间形成粘结的方法，所述方法包括步骤：
在所述第一叶片外壳和第二叶片外壳之间形成空腔(1448)；
将粘合剂(500)填充到所述空腔(1448)内，以便在所述第一叶片外壳和第二叶片外壳之间形成粘结缝。
2.根据权利要求1所述的方法，其特征在于，所述粘合剂(500)是注入或灌输到所述空腔(1448)内的。
3.根据权利要求1或2所述的方法，其特征在于，在所述第一叶片半和第二叶片半中的至少一个内形成开槽(1444)，以便当所述第一叶片半和第二叶片半相互安装时由所述开槽(1444)形成所述空腔(1448)。
4.根据上述权利要求中任一项所述的方法，其特征在于，将软管(900)设置在所述空腔(1448)内，而所述粘合剂(500)通过所述软管(900)注入。
5.根据权利要求4所述的方法，其特征在于，所述软管(900)在注入粘合剂(500)的同时逐渐从所述空腔(1448)中收回。
6.一种用于在叶片的第一外壳和第二外壳之间形成粘结的方法，所述方法包括步骤：
在所述第一叶片外壳和第二叶片外壳之间形成空腔(1448)；
将可膨胀的粘合剂放置在所述空腔(1448)内；和
使所述可膨胀的粘合剂膨胀，以便在所述第一叶片外壳和第二叶片外壳之间形成粘结缝。
7.根据权利要求6所述的方法，其特征在于，将所述可膨胀的粘合剂放置于在至少所述第一叶片外壳内形成的开槽(1444)内，以及随后将所述第二叶片外壳安装在所述第一叶片外壳上，以便形成容纳所述可膨胀的粘合剂的所述空腔(1448)。
8.根据权利要求6或7所述的方法，其特征在于，所述可膨胀的粘合剂通过将其曝露于紫外光、使其受热、使用泡沫剂和/或使用化学硬化剂(550)的方式而膨胀。
9.一种用于风力涡轮机(100)转子叶片(140)的外壳，包括：
形成在粘结缝的区域内的开槽(1444)，使得所述开槽(1444)在由互补的叶片外壳覆盖时形成空腔(1448)。
10.根据权利要求9所述的叶片外壳，其特征在于，还包括在所述开槽(1444)和所述叶片外壳表面之间延伸的至少一个注入孔(1446)和/或至少一个排气孔(1447)。
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