CN102056730A - 制造涡轮叶片半部的方法、涡轮叶片半部、制造涡轮叶片的方法和涡轮叶片 - Google Patents

制造涡轮叶片半部的方法、涡轮叶片半部、制造涡轮叶片的方法和涡轮叶片 Download PDF

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CN102056730A
CN102056730A CN2009801177400A CN200980117740A CN102056730A CN 102056730 A CN102056730 A CN 102056730A CN 2009801177400 A CN2009801177400 A CN 2009801177400A CN 200980117740 A CN200980117740 A CN 200980117740A CN 102056730 A CN102056730 A CN 102056730A
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turbo blade
stiffener
base portion
fibrofelt
resin
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CN2009801177400A
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CN102056730B (zh
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G·J·万辛克
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Xemc Darwind BV
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Xemc Darwind BV
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    • 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
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    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
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    • B29D99/0028—Producing blades or the like, e.g. blades for turbines, propellers, or wings hollow blades
    • 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
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
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Abstract

本发明涉及一种利用树脂浸渍模制生产涡轮叶片半部(1、2)的方法。根据本发明，所述方法包括步骤：在用于涡轮叶片壳的模具(3)中设置纤维毡(4)；将加强构件(6)设置在模具中的纤维毡上；在纤维毡上并紧靠加强构件设置不透气的密封层(17)；在低压下将可固化的树脂引入包括在加强构件下方的区域中的纤维毡；和使树脂固化以形成涡轮叶片半部，所述涡轮叶片半部包括附连至加强构件的涡轮叶片壳。本发明还涉及一种涡轮叶片半部、一种生产涡轮叶片(123)的方法、并涉及一种涡轮叶片。

Description

制造涡轮叶片半部的方法、涡轮叶片半部、制造涡轮叶片的方法和涡轮叶片
技术领域
本发明涉及一种通过树脂浸渍模制制造涡轮叶片半部的方法。
背景技术
近年来，大量生产的风力涡轮的发展已朝使它们在输出和尺寸上越来越大的方向前进。该过程需要更好和更具成本效益的部件和制造方法，并且以上情形对制造费时的风力涡轮叶片尤其适用。本领域已知的风力涡轮叶片通常由通过金属、木材或碳纤维增强的玻璃纤维制成。叶片通常通过在两个独立的模具中模制和固化两个叶片半部制成。随后，例如利用EP 1695813的方法给待连接的叶片半部的表面区域提供粘合剂(环氧树脂)，并使半部相互叠置并相互连接。通常，风力涡轮叶片包含诸如桅杆的加强构件。这样的加强构件提高强度并帮助维持风力涡轮叶片的合适的空气动力形状。
涡轮叶片的制造具有的问题是其费时并且昂贵。例如，用于具有55m的长度的一对风力涡轮叶片半部的模具可花费C1M。如果涡轮叶片的生产缓慢，则以上情形明显为成本作出贡献。
发明内容
因此，本发明的目的是提供一种以较少的时间生产涡轮叶片半部的方法。
为此，本发明提供一种利用树脂浸渍模制生产涡轮叶片半部的方法，所述方法包括步骤：
在用于涡轮叶片壳的模具中设置纤维毡；
将加强构件设置在模具中的纤维毡上；
在纤维毡上并紧靠加强构件设置不透气的密封层；
在低压下将可固化的树脂引入包括在加强构件下方的区域中的纤维毡中；以及
使树脂固化，以形成涡轮叶片半部，所述涡轮叶片半部包括附连至加强构件的涡轮叶片壳。
因此，本发明将使涡轮叶片壳固化的步骤和将加强构件附连至涡轮叶片壳的步骤结合成单个步骤。在本申请中，术语“涡轮叶片”、或简称的叶片包括涡轮叶片中的一类、诸如失速型涡轮叶片。用于该方法的树脂便利地为常规地利用树脂注射模制(RIM)制造用于风力涡轮叶片的树脂。用于RIM的典型树脂是利用热例如在75℃处固化的环氧树脂。类似地，纤维毡优选地为玻璃纤维毡。如果人们围绕固化树脂缠绕绳以将加强元件连接至涡轮叶片壳，则通常由绳围绕的表面区域的至少40％、优选的至少60％并且更优选的至少80％是不包括泡沫的固化树脂。通常，在低压下，加强构件最靠近纤维毡的部分与纤维毡相隔小于3mm、例如大约2mm。优选地，术语“在...上方”指的是“在...之上”。
根据优选实施例，加强构件是包括固化树脂的纤维增强构件。
这导致形成的涡轮叶片半部是轻的，并且由热表现(由于温度而膨胀/收缩)在很大的程度上相似的部件组成。树脂优选地为相同的类型，即包括涉及固化反应的相同类型的化学族。这增强了壳与加强构件的结合。通常，固化树脂与用于涡轮叶片半部的相同。
根据优选实施例，纤维增强构件包括基部，该纤维增强构件是在紧靠基部存在表面区域增大的衬里的同时固化的树脂，并且该方法包括在将加强构件设置在模具中的纤维毡上之前移除衬里的步骤。
根据优选实施例，加强构件包括长形基部、从所述基部延伸的纵向壁、和在所述壁的与所述壁从基部延伸的位置相对的边缘处从所述壁延伸的凸缘。
这样的凸缘可以并且将用于将其结合至第二涡轮叶片半部的对应凸缘，以形成涡轮叶片。这增大两半部的加强构件接合的表面区域，并因此提高强度。与基部大致平行的凸缘便于可固化树脂的涂覆。
更优选地，使用加强构件，其具有：
长形基部；
在所述长形基部的相对的边缘处从所述长形基部延伸的两个纵向壁；
其中，各纵向壁具有从相应的壁延伸的凸缘，所述凸缘彼此远离地延伸。
因此，能提供非常简单然而坚固并且硬的涡轮叶片半部。
根据优选实施例，涡轮叶片壳具有前缘和后缘，并且凸缘具有背离基部的凸缘区域，所述凸缘区域处于由前缘和后缘限定的平面中。
凸缘连接至另一涡轮叶片半部的相对凸缘。由于在使用期间经受风力，在接合处的剪切载荷最小，所以这允许具有增强的强度的涡轮叶片的制造。
根据优选实施例，加强构件通过双面密封剂层附连至密封膜。
这是获得令人满意的密封以在低压下执行树脂的引入的非常便利的方式，该压力通常约为大气压力的2％。为了以最实用的方式工作，加强构件设置有双面密封剂层，因而制造涡轮叶片半部的人们只需要使用密封膜。密封剂层是特殊类型的双面胶带，其是无孔的并为此能够维持真空。
本发明涉及一种能利用根据本发明的方法制造的涡轮叶片半部。
本发明还涉及一种制造风力涡轮叶片的方法，其中，通过如下步骤获得风力涡轮叶片半部：
使用于涡轮叶片壳的模具设置有纤维毡；
设置加强构件，其包括基部、从所述基部延伸的壁、和在模具中的纤维毡上方在所述壁的与所述壁从所述基部延伸的位置相对的边缘处从所述壁延伸的凸缘；
在纤维毡上方并紧靠加强构件设置不透气的密封膜；
在低压下将可固化的树脂引入包括在加强构件下方的区域中的纤维毡；以及
使树脂固化，以形成涡轮叶片半部，
所述涡轮叶片半部包括通过固化树脂附连至加强构件的涡轮叶片壳并具有前缘和后缘，所述涡轮叶片半部连接至第二涡轮叶片半部，使得两个半部的前缘和所述两个半部的后缘被连接，并且第一涡轮叶片半部的加强构件的凸缘连接至第二涡轮叶片半部。
至少就所关心的前缘和后缘而言，第二涡轮叶片半部的周边是第一涡轮叶片半部的镜像，即周边一致(具有相同的尺寸和形状)。优选地还根据本发明利用生产涡轮叶片半部的方法制造第二涡轮叶片半部。
根据一重要的实施例，各涡轮叶片半部包括具有凸缘的加强构件，并且连接相对的涡轮叶片半部的凸缘。
这形成非常坚固的风力涡轮叶片。
通常，利用可固化的树脂连接半部。
除了该可固化的树脂包含填料以增强其粘性以外，该可固化的树脂优选地与用于制造涡轮叶片半部的树脂相同。另外地或替代性地，该可固化的树脂可具有较高的分子量。
对于制造涡轮叶片半部的方法所讨论的所有优选的实施例可等同地适用于制造涡轮叶片的方法，并由本申请所保护，但仅为了简洁起见不再进一步重复。
最后，本发明涉及一种能利用根据本发明的方法制造的涡轮叶片。
附图说明
现在将参考附图说明本发明，其中：
图1a-1d以横断面视图示出涡轮叶片半部的制造中的步骤；
图2示出图1的叶片的顶视图；以及
图3示出涡轮叶片的制造中的步骤。
具体实施方式
参考图1a-1d详述制造玻璃纤维增强环氧树脂的风力涡轮叶片半部1的方法。生产玻璃纤维增强环氧树脂的涡轮叶片半部1、2的技术在本领域为大家所熟知，因此，说明将集中在根据本发明的方法与已知方法不同的方面。
图1a示出用于风力涡轮叶片壳1的模具3。模具3设置有玻璃纤维毡4。还可使用其他类型的毡、诸如由超强力纤维制成的毡。在玻璃纤维毡之上，设置有具有比玻璃纤维毡4松散的结构的也称为浸渍网状物的另一毡5(图1b)。该另一毡5可以由或可以不是由诸如玻璃纤维、碳纤维、DyneemaTM等的增强材料制成。
在该另一毡5之上设置有U形梁6，该U形梁6具有长形基部7(图2)、在基部7的长度上延伸的两个侧壁8、8′以及凸缘9、9′。该另一毡5帮助确保环氧树脂将达到玻璃纤维毡4的每个部分，即使其在U形梁6之下。U形梁6为加强构件，并向完成的涡轮叶片123提供提高的结构强度和帮助维持其空气动力形状。如本领域所知的，U形梁6由玻璃纤维毡和环氧树脂制成。环氧树脂可以与在基部的与侧壁相对的侧面处存在的纹理剥离层(例如单股尼龙剥离层)接触的方式被固化。在将U形梁6设置于该另一毡5之上之前移除该剥离层(未示出)，以提供表面区域增大的粗糙表面，从而随后在处理中增强U形梁6与环氧树脂之间的粘着强度。通过正好在将U形梁6设置在该另一毡5之上之前移除剥离层，粗糙表面区域不会被污染(诸如灰尘、油脂等)。
在将U形梁6设置在该另一毡5之上之前，使该U形梁6设置有双面密封剂层10、10′。密封剂层10、10′合适地为非硫化丁基橡胶。其作为两防粘衬里之间的非硫化丁基橡胶层被销售。
通常，涡轮叶片半部1的壳11为复合材料，通常为纤维毡增强固化树脂层12、泡沫层13和另一纤维毡增强固化树脂层14的夹层。然而，对于最坚固的风力涡轮叶片123，重要的是，加强构件6在树脂大的有效横截面积(与壳11平行的横截面积)上与浸渍在最靠近模具3的纤维毡4中的树脂直接并且充分地接触。通常，具有在加强元件下方延伸的泡沫层13是不合需要的。如果在基部7下方的足够的表面区域为固化树脂，则这是可接受的但仍不值得推荐。
为了便于空气的排空和环氧树脂的引入，Ω形轮廓15通过其开放侧设置到玻璃纤维毡上(图1c)，所述Ω形轮廓15用作用于运输和分配可固化树脂的通道。如果使用泡沫层13，则其包含通孔(未示出)，以允许可固化的树脂传到最靠近模具3的纤维毡4。然而，泡沫13本身可以是无孔泡沫，以获得最佳的强度。
随后，用一次性塑料膜17覆盖玻璃纤维毡4(或玻璃纤维毡4、泡沫层13和另一玻璃纤维毡层16的夹层)和Ω形轮廓。利用双面密封剂层10、10′使塑料膜17相对于U形梁6密封。利用真空泵(未示出)从塑料膜17下面去除空气(箭头)，并在维持真空的同时引入可固化的环氧树脂。环氧树脂穿过塑料膜17之下所有的空隙，以进入玻璃纤维毡4和该另一毡5。随后，以高温(例如75℃)使环氧树脂固化。这不仅导致涡轮叶片壳11固化，而且同时将涡轮叶片壳11结合至U形梁6。由于不再需要冷却壳、涂覆环氧树脂和U形梁、以及加热组件以使环氧树脂固化，所以节省了宝贵的时间。
在使可固化的树脂固化之后，通过加热模具3去除塑料膜17和Ω形轮廓15。
图2示出涡轮叶片半部1的顶视图，其中U形梁6在涡轮叶片半部1长度的大部分上延伸。
生产涡轮叶片123可简单地通过如下步骤实现：利用根据本发明的上述方法制造两个涡轮叶片半部1、2，将含填料的环氧树脂涂覆在涡轮叶片半部1的形成接触的表面处、尤其是两个涡轮叶片半部1、2中的至少一个的U形梁6的凸缘9、9′以及前缘18和后缘19，随后将涡轮叶片半部1、2彼此相对设置和使环氧树脂固化。通过加热模具3、3′使环氧树脂固化。
如图3中所看到的，凸缘9、9′在由前缘18和后缘19限定的平面中具有表面。凸缘9、9′本身提供较大的表面区域(结合区域20、20′)，以使涡轮叶片半部1、2结合在一起。结合本身处于在涡轮叶片123中的力平均起来比U形梁6中的别处小的位置，形成较坚固的风力涡轮叶片123。

Claims (12)

1.一种通过树脂浸渍模制生产涡轮叶片半部(1、2)的方法，所述方法包括以下步骤：
在用于涡轮叶片壳(11)的模具(3)中设置纤维毡(4)；
将加强构件(6)设置在所述模具(3)中的所述纤维毡(4)上方；
将不透气的密封膜(17)设置在所述纤维毡(4)上方并紧靠所述加强构件(6)；
在低压下将可固化的树脂引入所述纤维毡(4)中，包括在所述加强构件(6)下方的区域中的所述纤维毡(4)中；以及
使所述树脂固化，以形成涡轮叶片半部(1、2)，所述涡轮叶片半部(1、2)包括通过已固化的树脂附连至所述加强构件(6)的涡轮叶片壳(11)。
2.根据权利要求1所述的方法，其中，所述加强构件是包括固化树脂的纤维增强构件。
3.根据权利要求1所述的方法，其中，所述纤维增强构件包括基部(7)，所述纤维增强构件是在一表面区域增大的衬里紧靠所述基部存在时被固化的树脂，并且所述方法包括在将所述加强构件设置在所述模具(3)中的所述纤维毡(4)上方之前移除所述衬里的步骤。
4.根据前述权利要求中任一项所述的方法，其中，所述加强构件(6)包括：长形基部(7)，从所述基部(7)延伸的纵向壁(8、8′)，以及在所述壁(8、8′)的、与所述壁(8、8′)从所述基部(7)延伸的位置相对的边缘处、从所述壁(8、8′)延伸的凸缘(9、9′)。
5.根据权利要求4所述的方法，其中，使用加强构件(6)，该加强构件具有：
长形基部(7)；
在所述长形基部(7)的相对的边缘处从所述长形基部(7)延伸的两个纵向壁(8、8′)；
其中，每个所述纵向壁(8、8′)具有从相应的所述壁(8、8′)延伸的凸缘(9、9′)，所述凸缘(9、9′)彼此远离地延伸。
6.根据权利要求5所述的方法，其中，所述涡轮叶片壳(11)具有前缘(18)和后缘(19)，并且所述凸缘(9、9′)具有背离所述基部(7)的凸缘区域(20、20′)，所述凸缘区域(20、20′)处于由所述前缘(18)和所述后缘(19)限定的平面中。
7.根据前述权利要求中任一项所述的方法，其中，所述加强构件(6)通过双面密封剂层(10、10′)附连至所述密封膜(17)。
8.一种能够利用根据权利要求1至7中任一项所述的方法制造的涡轮叶片半部。
9.一种制造风力涡轮叶片(123)的方法，其中，通过如下步骤获得第一涡轮叶片半部(1)：
在用于涡轮叶片壳的模具中设置纤维毡；
设置加强构件，该加强构件包括：基部，从所述基部延伸的壁，以及在所述模具中在所述纤维毡上方、在所述壁的与所述壁从所述基部延伸的位置相对的边缘处、从所述壁延伸的凸缘；
将不透气的密封膜设置在所述纤维毡上方并紧靠所述加强构件；
在低压下将可固化的树脂引入所述纤维毡中，包括在所述加强构件下方的区域中的所述纤维毡中；以及
使树脂固化，以形成第一涡轮叶片半部，所述第一涡轮叶片半部包括通过已固化的树脂附连至所述加强构件的涡轮叶片壳，
所述第一涡轮叶片半部还具有前缘和后缘，
所述第一涡轮叶片半部(1)连接至一第二涡轮叶片半部(2)，使得两个半部的前缘和所述两个半部的后缘被连接，并且所述第一涡轮叶片半部的所述加强构件的所述凸缘连接至所述第二涡轮叶片半部。
10.根据权利要求9所述的方法，其中，每个涡轮叶片半部均包括具有凸缘的加强构件，并使相对的各涡轮叶片半部的所述凸缘相连接。
11.根据权利要求9或10所述的方法，其中，利用可固化的树脂使所述第一涡轮叶片半部和所述第二涡轮叶片半部相连接。
12.一种能够利用权利要求9至11中任一项制造的涡轮叶片。
CN2009801177400A 2008-05-16 2009-05-14 制造涡轮叶片半部的方法、涡轮叶片半部、制造涡轮叶片的方法和涡轮叶片 Expired - Fee Related CN102056730B (zh)

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