CN102216055A - 用纤维材料制造层压部件的方法 - Google Patents

用纤维材料制造层压部件的方法 Download PDF

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CN102216055A
CN102216055A CN2009801451689A CN200980145168A CN102216055A CN 102216055 A CN102216055 A CN 102216055A CN 2009801451689 A CN2009801451689 A CN 2009801451689A CN 200980145168 A CN200980145168 A CN 200980145168A CN 102216055 A CN102216055 A CN 102216055A
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preform
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丹尼斯·安德烈·伯尔斯廷
周嵚崟
雅各布斯·约翰内斯·范德泽
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LM Wind Power AS
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/54Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/541Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/22Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using layers or sheathings having a shape adapted to the shape of the article
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping 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
    • B29C70/38Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/08Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082Blades, e.g. for helicopters
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10Methods of surface bonding and/or assembly therefor
    • Y10T156/1052Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/12Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

本发明提供了一种制造如风力发电设备用的叶片的纤维强化部件的方法,其中将许多包括纤维(如玻璃纤维垫)的材料层(10)布置在细长(5)敞口模具(1)的弯曲表面(5)上,其中将每个材料层(10)以预成形垫(10)的形式布置在所述弯曲表面(5)上,预成形垫具有基本上对应于预期施加区域的形式,因此基本消除了进一步修整或切割所述材料的任何需要。

Description

用纤维材料制造层压部件的方法
根据一个方面,本发明涉及制造用于风力发电设备的纤维强化部件(如叶片)的方法,借此将多个包括纤维的材料层(如玻璃纤维垫)布置在细长敞口模具(open mould)的弯曲表面上。
背景技术
在制造用于风力发电设备的纤维强化部件(如叶片)的背景下,通常采用这样的制造过程:其中部件在两个半部各自的敞口模具中模制成两个半部,其中最初将例如凝胶体涂层的涂层施加在该敞口模具的内表面上。
随后通常通过手工将许多纤维材料层或垫布置在模具中,在此之后通常通过注射将树脂施加到闭合模具(closed mould)中,从而使单独的纤维材料层彼此附接。可通过RTM(树脂传递模塑)、VARTM(真空辅助树脂传递模塑)或其他合适的方法将树脂手动地施加到这些层上。替换地,可在放置这些层之前将树脂施加到这些层压层上(Prepeg,预浸料)。在这种背景下,凝胶体涂层将硬化并形成产品的表面。
这些层通常作为包括“无尽”长度的材料的卷那样被提供给该过程,其布置在模具上并随后被切割以适合待制造部件的形状。
当前,将纤维材料层布置在模具内部中并(通过切割)使其成形的过程耗时且劳动强度大。根据待制造部件的尺寸,并因而根据模具的尺寸,可将通道(walkway)布置在模具的侧面和/或上面,从而使得工人可以沿着模具的边缘或周界(periphery)和/或在模具上面行走,以便根据需要布置和切割这些纤维材料层。
在铺设(layup)纤维材料期间,由于该纤维材料笨重且不容易操作,因此需要数个工人共同努力。一些工人协助展开(rollout)材料,而沿着模具边缘的其他工人确保这些层被正确地铺设。
为了确保待制造部件具有期望的形状、外观、强度和稳定性,最为重要的是在不产生凹痕(dent)或折皱(wrinkle)等的情况下正确地布置和切割这些层。
根据待制造部件的应用和结构,可将多个纤维材料层布置在模具上,并且通常将这些层布置在彼此的顶部,或者在边缘有可能交叠的情况下彼此相邻地布置。
这些部件通常由多达50或更多的材料层组成,并且这些部件通常是从设置在模具中央的主层压物而逐渐累积(build up)起来的。
在将一从卷提供的层布置在模具上之后,从该卷上切割材料。制造沿着部件的整个长度具有曲率的部件(如风力发电设备的翼板(wing)),可能需要沿着该模具边缘进行很长的切割。
用于制造此种部件的模具可能非常大,因而该模具价格昂贵。应当将把材料布置在模具上所需的时间减到最少,以便将待制造部件所需的形成时间(部件占据该模具的时间)减到最少,从而增加该模具的总体生产力。
GB 2156729 A教导了模制强化材料的方法,其中将预浸渍强化材料(如玻璃纤维垫)应用于模制过程中。该强化材料可以“无限定长度的”,在这种情况下铺设层压物的过程需要刀具,或者将预切割长度的垫提供给该过程,其中切割由布置在模具附近的切割台(cutting station)提供。在将该材料布置到模具上之前,该切割台可以在基本横切于材料运送方向的方向上切割材料。
优选地,基本均匀而且平齐地(flush)布置纤维材料,这就是应当消除所形成的任何凹痕、折皱或卷曲等的原因。进一步地,因为通常将一层施加在在先的层的顶部上,所以下部层以及包括布置在下部层下面的可能的额外层会倾向于在模具内移动或滑动,致使整个所铺设的纤维材料移动远离模具内的预期位置。因此,应当将对布置在模具上的材料的任何操作或处理减到最少,这就是为什么期望这样的制造过程,其中除去了在将垫布置在模具上的同时切割这些垫的步骤。
因而,本发明目的在于提供对于上述缺陷的解决方案。
这通过这样的方法实现:制造根据本说明书引言部分的纤维强化部件,其中将每个垫以预成形垫的形式布置在模具弯曲表面上,这些预成形垫具有基本上对应于预期施加区域的形式,从而基本消除了进一步修整或切割垫的任何需要。
根据本发明的方法基本上减少了制造部件所需的形成时间,进一步地,该方法能够减少工人铺设这些垫所需的努力。
如权利要求2所述,当从一个或多个卷(其设置在适合于沿着所述细长模具的运送的通道或运货车(cart)上)展开或拉出(drawn)这些预成形垫时,在铺设期间损坏这些层的几率大大降低并且铺设所需的人力减到最少。
如权利要求3所述,当将一个或多个卷布置为包括各自均包括不同的预成形垫的多个卷的“旋转式鼓状物(revolver drum)”时,大大优化了通过这些卷供应(accommodate)的垫的处理和接近途径。
根据一个实施例,该预成形垫为(constitute,构成)从一个或多个材料卷上切割的预切割垫。
如权利要求5所述,当根据预定位置的图案(pattern)将这些预成形垫布置在模具上时,提高了铺设速度以及最终产品的质量。
根据一个实施例,这些预定位置为借助光确立在模具上的图案。
根据一个实施例,这些预成形垫从这样的装置提供,该装置适于预切割从卷拉出的“无尽”长度的材料。
根据一个实施例,这些预切割垫被卷到一个或多个卷上并卷成一个或多个层。
如权利要求10所述,当这些预成形垫具有识别(identification)形式时,利于铺设的控制和文件编制(documentation)。
附图说明
图1示出了被纤维垫层覆盖的敞口模具。
图2示出预成形纤维垫。
图3示出敞口模具。
具体实施方式
图1示出覆盖敞口模具1的三个并列长度的纤维材料20的主俯视图,该敞口模具1具有由周界6限定的弯曲表面5。模具1以及弯曲表面5的周界6用虚线示出。
模具1通常可为长度基本相当于待制造的部件或子部件(sub-part)的长度的细长模具。
根据制造纤维强化部件的当前方法,将通常从一个或多个卷(未示出)展开(unroll)的一个或多个层20布置在模具1上,以便覆盖弯曲表面5。
一旦布置至少一种长度的材料以使得弯曲表面5被覆盖,则沿着边缘或周界6切割该材料,以便材料被切割后的长度适合于模具1内的预期位置。
由于提供给模具1的材料宽度有限,因此一个材料层通常由并排地或交叠地布置在模具1上的数个子块(sub-pieces)组成。
上覆的层或上方的层可以布置在模具1上,以便下面的层或下方的层交会的线或区域被在上覆的层或上方的层覆盖,换言之,布置在模具1上的垫的位置可以在基本上垂直于模具1纵轴线的方向上移动。
如图所示,通常有必要沿着弯曲表面5的整个周界或边缘6进行切割。
由于用于制造构件(如风力发电设备用的叶片)等的模具等可能非常大,通常超过60米,并且多达50层(堆积或堆放)或更多的层被布置在模具上,因此切割材料的过程是一项艰巨的任务。
虽然该图中未示出,但是可以在模具1上布置厚度相对较大(可能多达50mm或更多)且宽度约为800mm的主层压物。
进一步地,但未在图中示出,可以在该垫之间可放入轻木(balsa wood),以便在这些垫的层之间获得期望的距离。轻木也可以用于根据本说明书的制造方法。
图2示出所制备的用于布置在模具1上的预成形纤维垫10。该预成形垫10可以由子供应商提供或可在邻近的制造站制造。
预成形纤维垫10可以在卷到一个或多个未示出的卷上时被提供给该过程。这些卷可以为“旋转式鼓状物”(未示出),该旋转式鼓状物配置成用于提供两个或更多个卷,以使得可以在不扰乱铺设一个或多个纤维材料层的过程的情况下将所成形的具有变化特性的纤维垫布置在模具1上。
该预成形垫可具有标记物(marking)11,其有利于垫在模具1上的铺设。
可以生产(制造或编织)预成形纤维垫10以便获得特定形状,或作为等同的替换物,从材料卷中切割成形。
用于实现切割的装置可以为切割辊筒(cut-roll)、刀片/叶片、激光器、任何类型的爆破切割(blast-cutting)、规格切纸(cut form)等,并且这些层预成形的过程可以为自动和/或处理器控制的过程。
图3示出空的敞口模具1。制造根据本发明的纤维强化部件的方法可以包括在模具1的弯曲表面5上、或着在布置在模具1上的垫上建立标记物的步骤,如图中用虚线7表示的。该标记物7可通过设置在模具1的弯曲表面5上的闪电(lightning)或照明装置(未示出)建立。
一旦将材料层(预成形或未预成形)布置在模具1上,工人就可以根据标记物7对齐该材料,以便可以相对容易地获得在模具1上的预期材料位置。
闪电装置可以针对不同目的而改变标记物,例如使得标记物7在铺设完成时变化。
可以提供记录影像或静止图片的装置,以便可以提供铺设材料的过程的控制和/或文件编制。
闪电装置以及照相机可以用未示出的处理器(如计算机)加以控制。
须理解,可对本说明书及附图中公开的本发明进行调整或修改,且这些调整或修改仍然包括在下面权利要求限定的保护范围内。

Claims (10)

1.一种制造纤维强化部件的方法,所述纤维强化部件比如为用于风力发电设备的叶片,其中将多个包含纤维的材料层(10)布置在细长敞口模具(1)的弯曲表面(5)上,所述包含纤维的材料层比如为玻璃纤维垫,其特征在于,将每个材料层(10)作为预成形垫(10)布置在所述弯曲表面(5)上,所述预成形垫(10)具有基本上对应于预期施加区域的形式,以使得基本上无需进一步修整或切割所述材料。
2.根据权利要求1所述的方法,其中,所述预成形垫(5)从设置在适合于沿着所述细长模具(1)的运送的通道或运货车上的一个或多个卷展开或拉出。
3.根据权利要求2所述的方法,其中,将所述一个或多个卷布置为包括多个卷的“旋转式鼓状物”,每个卷均包括不同的预成形垫(10)。
4.根据前述权利要求中任一项所述的方法,其中,所述预成形垫(5)为从一个或多个材料卷上切割的预切割层。
5.根据前述权利要求中任一项所述的方法,其中,根据预定位置的图案将所述预成形垫(5)布置在所述模具上。
6.根据前述权利要求中任一项所述的方法,其中,根据在所述模具(1)上表示的预定位置的图案将所述预成形垫(5)布置在所述模具上,其中所述图案通过光建立在所述模具(1)上。
7.根据前述权利要求中任一项所述的方法,其中,所述预成形垫(5)从适于预切割所述材料的装置提供。
8.根据前述权利要求7所述的方法,其中,将所述预切割层(5)卷到一个或多个卷上并卷成一个或多个层。
9.根据前述权利要求中任一项所述的方法,其中,根据设置在所述预成形垫(5)上的标记物,将所述预成形垫(5)布置在所述模具(1)上。
10.根据前述权利要求中任一项所述的方法,其中,所述预成形垫(5)具有识别形式。
CN2009801451689A 2008-11-12 2009-11-11 用纤维材料制造层压部件的方法 Pending CN102216055A (zh)

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