CN102248687B - 模制风力涡轮机叶片的方法 - Google Patents
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Abstract
本发明描述了在模具中模制风力涡轮机叶片的方法,该方法包括如下步骤:向所述模具的内侧表面施加膜;在所述膜上组装用于所述风力涡轮机叶片的部件层;执行固化步骤以使得所述部件层硬化;以及随后从所述模具移除固化的风力涡轮机叶片。本发明还描述了适用于风力涡轮机叶片模制过程的膜,该膜包括给模具加衬的外侧表面以及用于在固化之前接收风力涡轮机叶片部件层的内侧表面,并且其中所述膜的所述内侧和外侧表面被实现为允许在固化之后从所述模具完全拆除固化的风力涡轮机叶片。本发明还描述了用于模制风力涡轮机叶片的模具,包括适于接收这种膜的内侧表面以及用于施加真空以便从所述膜和所述模具内侧表面之间抽吸空气的抽真空出口。
Description
技术领域
本发明描述了模制风力涡轮机叶片的方法、在风力涡轮机叶片模制过程中使用的膜以及在模制风力涡轮机叶片过程中对这种膜的使用。
背景技术
可以使用诸如闭合模具铸造技术的技术来制造风力涡轮机转子叶片,在该闭合模具铸造技术中能够模制整个叶片。玻璃纤维垫可以被用于在适当的成形模具中构建部件层,并且使用树脂来粘结垫层且所述垫层在模具中固化从而得到纤维增强的聚合物或玻璃增强的塑料,通常被简化地称为“纤维玻璃”。这样的方法在EP1310351A1中被描述。
为了有助于在固化之后释放完工的纤维玻璃部件,模具通常涂覆有释放剂,例如适当的蜡,以便树脂不会粘结于模具。在构建纤维玻璃层之前将释放剂应用于模具。公知的释放剂是聚乙烯醇、硅酮蜡、滑动蜡等。释放剂必须以均一层被应用,并且如果固化的叶片的外表面是平滑的话则这个层也必须绝对平滑。不过,难以应用这样的释放剂来满足这些要求,并且可能导致不均匀或带有波纹的部件表面。此外,常用的释放剂类型包含挥发性溶剂,其对于暴露于该挥发性溶剂的任何人会造成健康危害。不过,必须使用这种释放剂的主要缺点在于,在固化之后,释放剂的残余物会当场附着于叶片。释放剂的这些残余物必须在时间密集型过程中被去除,例如洗涤或喷砂过程,从而增加了整体的制造成本。
发明内容
因此,本发明的目标在于提供通过模制来制造风力涡轮机叶片的改进方式,从而克服上述问题。
通过根据权利要求1所述的模制风力涡轮机叶片的方法、权利要求9的膜、根据权利要求12的用于模制风力涡轮机叶片的模具以及根据权利要求14的这种膜和这种方法在风力涡轮机叶片的模制中的使用来实现本发明的目标。
根据本发明的在模具中模制风力涡轮机叶片的方法包括如下步骤:向模具的内侧表面施加膜;在膜上组装用于风力涡轮机叶片的部件层;执行固化步骤以便使得部件层硬化;以及随后从模具拆下固化的风力涡轮机叶片。
本方法的显而易见的目的在于膜省去了对于释放剂的需求,从而不再必须使用释放剂涂覆模具的内侧表面(或“内部表面”),并且不再必须从固化的风力涡轮机叶片去除释放剂的残余物。以此方式,在制造过程中可以实现显著的节约,且不用必须使用昂贵的预先准备的模具。取而代之的是,能够简单地铺设单片膜来给模具加衬。在固化之后,能够从风力涡轮机叶片容易地拆除膜,如下文将详细解释的。
根据本发明,适用于风力涡轮机叶片模制过程的膜包括给模具的内部表面加衬的外侧表面以及用于在固化之前接收风力涡轮机叶片的部件层的内侧表面,并且其中膜的内侧和外侧表面被实现为允许在固化之后从模具完全拆除固化的风力涡轮机叶片。
根据本发明的一个方面,用于模制风力涡轮机叶片的模具包括适于接收这种膜的内侧或内部表面以及用于施加真空以便从膜和模具的内侧表面之间抽取空气的抽真空出口。
根据本发明,这种膜可以使用本发明的模制方法被用于风力涡轮机叶片的模制过程中。
如下述说明书所述,从属权利要求给出了本发明的具体优选实施例和特征。实施例的特征可以根据需要被组合以便得到其他实施例。
根据本发明的方法特别适用于模制必须轻质且需要适用于应用涂料的平滑外表面的大型风力涡轮机叶片。因此,在本发明的优选实施例中,要被模制的部件包括由适当材料制成的层,例如玻璃纤维或碳纤维,使用诸如树脂、胶、热固性塑料等的纤维增强物来粘结所述层。可以以多种方式来实现粘结。例如,在手工铺层步骤中干燥纤维玻璃垫可以被涂覆有树脂。可替换地,可以使用事先浸渍的纤维材料(公知为“预浸渍料”),其通过加热、施加UV辐射等方式被固化。
根据本发明的方法能够被用于需要在固化之前在模具上铺设层且随后从模具移除层的任意模制技术。例如,能够通过模制两个半壳来制造实质中空的风力涡轮机叶片,其中所述两个半壳之后在前缘和后缘处通过将其胶粘在一起而被结合。能够通过在半壳的内侧面粘结一个或更多个梁来为该结构提供额外支撑。不过,由于半壳和用于沿其整个长度将其粘结在一起的胶的不同材料特性(例如弹性模量)的原因,可能难以确保胶粘接头具有令人满意的质量。在风力涡轮机叶片的情况下,这些胶粘接头存在潜在的薄弱性并且最终可能会因为作用在叶片上的极端力而断裂或分开。因此,在本发明的具体优选实施例中,模具包括用于以单件形式制造风力涡轮机叶片的闭合模具。在闭合模具方法中,纤维玻璃垫能够围绕芯被设置且这种结构之后能够被包罩在模具内。在模具已经闭合之后,诸如树脂或胶的纤维增强物能够事先被施加或引入到模具内。在固化之后,模具被打开并且能够移除风力涡轮机叶片。使用这种方法,可以以单件形式制造诸如风力涡轮机叶片的大型中空部件并且不会存在具有任意潜在危险的胶粘接头。
用于给模具加衬的膜能够包括不粘附于固化的部件层的任意适当材料,不管这些层是否包括树脂填充的纤维层、热固性塑料层、预浸渍层等。因此,在本发明的具体优选实施例中,膜包括聚乙烯、聚丙烯或任意其他适当塑料,例如用于制造“紧附膜”或“保鲜膜”的膜类型。膜的一个或两个表面可以具有不粘附的特性,以便能够容易地从固化的风力涡轮机叶片和/或模具移除膜。在膜表面的上下文中术语“不粘附”被理解为表面具有阻止其他材料粘附于该表面的特性。例如,膜能够包括聚氯乙烯成分来减少其他材料粘附于膜的能力。用于给模具加衬的膜能够被容易地制成所需宽度,并且能够成卷供应以方便分配。
膜的厚度可以确定在模具上铺设的膜层的平滑度。明显地,膜应该足够柔韧以便其能够在不形成褶皱或折痕的情况下给模具加衬。另一方面,膜应该足够强劲以便允许其被拉离固化部件。因此,在本发明的优选实施例中,膜的厚度是至少20μm且至多200μm,更优选地至多100μm。
如上所述,对于膜而言理想的是具有尽可能平滑的表面,而没有褶皱或折痕,以便模制部件的表面将同样相应平滑。因此,在本发明的另一优选实施例中,方法包括如下步骤:在膜和模具的内部表面之间施加真空。能够通过经由位于膜和模具内侧表面之间的喷嘴抽出空气来施加真空。从膜和模具之间抽取空气能够确保膜平滑地给模具加衬。仅需要施加真空直到膜被充分地“压”到模具中。之后,能够停止抽真空并且部件层能够被构建在模具中。当然,如果需要的话,在铺设层的过程中也能够施加真空,例如为了防止膜滑动。
能够根据工艺要求来选择用于给模具加衬的膜的材料和结构。例如,如上所述,理想的是当从膜和模具之间通过真空来抽吸空气时获得尽可能平坦的表面。不过,在抽真空期间,可能的是膜被吸在模具的内侧表面上从而困住了小的气穴。因此,在本发明的具体优选实施例中,膜包括在被施加到模具的内侧表面的膜表面上的释放结构。这种释放结构可以包括诸如浅窝的凹陷或者凸起区域,并且能够用于改善固化之前铺设部件层的步骤期间膜与模具的内侧表面间的粘附。与模具的内侧表面紧密接触的膜是优选的以便当部件层被铺设在模具内时避免任意滑动。可替换地,释放结构能够包括在膜内的多个通道或沟槽,以便在膜和模具的内侧表面之间施加的真空能够最佳地抽出所有空气而不会允许存在任意显著的气穴。这样的通道或沟槽能够在膜制造(例如挤压过程中)期间容易地被成形并且优选地被设置成使得其位于实质上与抽吸的空气所处方向相同的方向,即沿真空喷嘴的方向。在具体简化实施方式中,膜包括沿其长度的平行沟槽或通道,并且膜沿长度方向被置于模具内,以便位于模具各端的真空喷嘴能够从膜和模具之间最佳地抽吸所有空气。
替代膜的外侧表面上的释放结构或除该结构之外,模具本身能够被实现为辅助抽真空步骤。因此,在本发明的优选实施例中,模具的内侧表面包括至少一个通道来有助于通过从膜和模具的内侧表面之间抽真空来去除空气。这样的通道能够被设置成沿模具的长度延伸、横跨模具的宽度延伸或者以有助于抽吸空气的任意适当方式延伸。优选地,模具包括多个通道,并且这些通道能够被设置成起始于或终止于真空喷嘴的附近,其中通过该真空喷嘴从膜和模具的内侧表面之间抽出空气。
在固化和从模具移除部件之后,膜可以附连于部件。根据膜的特性,其可以简单地留在部件上以用作外层。不过对于一些修整步骤(例如喷漆或涂漆)而言,可能优选的是将其移离实际部件表面。因此,在本发明的另一实施例中,方法包括如下步骤:在已经从模具移除部件之后从部件拆除膜,以便可以从部件剥离膜。膜可以简单地被剥离且被丢弃,不过耐用的膜会使得其本身能够在其他风力涡轮机叶片的模制过程中被再次使用。
不考虑在使用膜给模具加衬的过程中是否使用抽真空步骤,在移除固化部件时膜均可以保持在模具内。之后,可以简单地从模具剥离膜。不过,可能优选的是在固化后当移除叶片时使得膜从模具整个被拆除。因此,在本发明的另一优选实施例中,模具的内侧表面包括不粘附表面或内衬。例如,模具的内侧表面能够涂覆有例如Teflon®的材料,其具有有利的不粘附特性。
结合附图从下述具体描述中将显而易见到本发明的其他目标和特征。不过,应该理解,附图仅是图释性目的并且不作为对本发明的限制。
附图说明
图1示出了在现有技术部件模制过程中具有铺设的部件层的模具的横截面;
图2示出了在根据本发明的部件模制过程中具有铺设的部件层的模具的横截面;
图3示出了根据本发明的实施例的膜;
图4示出了从使用根据本发明的方法模制的风力涡轮机叶片拆除的膜。
具体实施方式
在附图中,在全部附图中,同样的附图标记指代同样的对象。图中的对象不必要成比例绘制。
图1示出了在现有技术部件模制过程中具有铺设的部件层10的模具2的横截面,该现有技术部件模制过程例如如EP1310351A1中所述,其中风力涡轮机叶片由纤维层10形成并且在闭合模具2中被固化,树脂在压力下被喷注到该模具2内。这里,模具2包括喷嘴21,在抽真空步骤期间能够通过喷嘴21抽吸空气,从而导致部件层10膨胀,并且借助于该喷嘴21,胶或树脂被抽吸到部件层10内。为了在不毁坏其表面的情况下从模具2移除固化的风力涡轮机叶片,诸如硅酮蜡的释放剂4的层被施加到模具2的内侧表面20,例如在图中的放大部分所示。当从模具2移除固化叶片时,蜡4的残余物会保持粘附于叶片1的外表面并且必须在额外步骤(例如洗涤或喷砂)中被去除。而且,在能够再次使用模具2之前,必须通过从模具的内侧表面20刮除释放剂层4来去除释放剂层4,或者释放剂层4必须被再次平整以便得到期望的均匀水平。
图2示出了在根据本发明的部件模制过程中具有铺设的部件层10的模具2的一部分的横截面。实质上,能够使用图1的模具。不过与图1所示的设置不同,取代了使用释放剂处理模具2的内侧表面20,而是使用膜3来给模具2加衬,如图中A部分所示。为了清楚的目的,由于膜3和模具2的相对厚度的原因,仅示出了整个设置的一个小区域。
通过从膜3和模具2之间抽吸空气,膜3能够最佳地被吸到模具2的内侧表面20上。为此,如图中B部分所示,在膜3和模具2之间施加真空,并且通过真空喷嘴21抽吸空气。之后,一旦模具2令人满意地内衬有膜3,则纤维材料(例如碳纤维、玻璃纤维、预浸渍物等)的层10能够根据需要被铺设,如图中C部分所示。模制过程的剩余物能够以常规方式被带出,其中抽真空步骤用于如图1所示通过真空喷嘴抽出空气从而允许部件层膨胀,并且固化过程用于使层硬化。明显地,单个真空喷嘴可以用于两个抽真空步骤,并且真空喷嘴可以被实现为针对第一抽取步骤被插在膜3和模具2之间并且针对第二抽取步骤被插在膜3和部件层10之间。图中的D部分示出了穿过B部分中的模具2和膜3截取的截面X-X’。这里,模具的内侧表面20内的额外通道22允许从膜3和模具2之间的空间更优化地抽吸空气。这里,通道22被设置在抽真空喷嘴21的方向上。
图3示出了根据本发明实施例穿过膜3的横截面。这里,膜3是丙烯或聚乙烯的薄膜3,且其厚度在20μm至100μm的范围内。将要接触部件层的膜3的“内侧表面”31优选地是平坦且平滑的。沿其长度在“外侧表面”32(即将与模具的内部表面接触的表面)上,膜3具有通道32或沟槽32。膜3优选地被放置到模具内以便这些沟槽32位于抽真空喷嘴的方向上。以此方式,能够在抽真空步骤期间从膜3和模具的内侧表面之间最佳地抽出空气。不过,抽真空步骤不是绝对必要的,因为也可以通过沿通道的方向展平而将膜手动地压到模具中。一旦膜令人满意地被压到模具中或吸到模具中从而得到令人满意的平滑表面,则能够在膜3的内侧表面31上铺设部件层以形成风力涡轮机叶片,如已经描述的那样。
图4示出了从使用根据本发明的方法模制的固化风力涡轮机叶片1拆除的膜3。如图所示,能够通过简单地剥离膜3来从固化叶片1容易地拆除膜3。假定给模具加衬的膜3产生了没有褶皱的平滑内衬,则固化叶片1的表面是平滑、干净、没有任何残余物并且准备好任意修整步骤(例如涂底或喷漆)的。
虽然这里已经以优选实施例和变型的形式公开了本发明,不过应该理解可以在不背离本发明范围的情况下做出大量其他修改和变型。例如,取代移除膜,还可以使用特定膜材料以便膜可以被留在固化的风力涡轮机叶片上。例如,如果膜的外侧表面具有适当特性,则其可以被包括在例如涂底或喷漆的任意后续修整步骤中,并且甚至可以提供保护功能。
为了简明的目的,应该理解,贯穿本申请书“一”或“一种”的使用不排除多个,并且“包括”不排除其他步骤或元件。除另外声明外,“单元”或“模块”能够包括多个单元或模块。
Claims (12)
1.一种在模具(2)中模制风力涡轮机叶片(1)的方法,该方法包括如下步骤:
向所述模具(2)的内侧表面(20)施加膜(3),所述膜(3)包括给所述模具(2)的内侧表面(20)加衬的外侧表面(30)以及用于在固化之前接收所述风力涡轮机叶片的部件层的内侧表面(20),其中所述膜(3)的所述外侧表面(30)包括释放结构、和/或所述模具(2)的所述内侧表面(20)包括至少一个通道(22)以有助于通过从所述膜(3)和所述模具(2)的所述内侧表面(20)之间抽真空来去除空气;
在所述膜(3)上组装用于所述风力涡轮机叶片(1)的部件层(10);
执行固化步骤以使得所述部件层(10)硬化;以及随后
从所述模具(2)移除固化的风力涡轮机叶片(1)。
2.根据权利要求1所述的方法,其中所述膜(3)包括聚乙烯和聚丙烯中的一者或更多者。
3.根据权利要求1或权利要求2所述的方法,其中所述膜(3)的厚度在20μm至200μm的范围内。
4.根据权利要求3所述的方法,包括如下步骤:在所述膜(3)和所述模具(2)的所述内侧表面(20)之间施加真空从而从所述膜(3)和所述模具(2)的所述内侧表面(20)之间抽吸空气。
5.根据权利要求1或权利要求2所述的方法,其中所述方法包括如下步骤:在已经从所述模具(2)移除所述风力涡轮机叶片(1)之后从所述风力涡轮机叶片(1)拆除所述膜(3)。
6.根据权利要求1或权利要求2所述的方法,其中所述模具(2)的所述内侧表面(20)包括不粘附内衬(20)。
7.根据权利要求1或权利要求2所述的方法,其中所述模具(2)包括闭合模具(2)。
8.根据权利要求1或权利要求2所述的方法,其中在所述膜(3)上组装部件层(10)的步骤包括铺设多个玻璃纤维层(10)。
9.一种适用于风力涡轮机叶片模制过程的膜(3),该膜(3)包括给模具(2)加衬的外侧表面(30)以及用于在固化之前接收风力涡轮机叶片部件层(10)的内侧表面(31),并且其中所述膜(3)的所述内侧表面和外侧表面(30,31)被实现为允许在固化之后从所述模具(2)完全拆除固化的风力涡轮机叶片(1);
其中所述膜(3)的所述外侧表面(30)包括释放结构以便从所述膜(3)和所述模具(2)的内侧表面(20)之间抽取空气。
10.根据权利要求9所述的膜(3),其中在所述膜(3)的所述外侧表面(30)上的所述释放结构包括多个通道(32)或沟槽(32)。
11.一种用于模制风力涡轮机叶片(1)的模具(2),包括适于接收根据权利要求9-10中任一项权利要求所述的膜(3)的内侧表面(20)以及用于施加真空以从所述膜(3)和所述模具内侧表面(20)之间抽吸空气的抽真空出口(21);
其中,所述模具(2)的所述内侧表面(20)包括至少一个通道(22)以有助于通过从所述膜(3)和所述模具(2)的所述内侧表面(20)之间抽真空来去除空气。
12.在根据权利要求1-8中任一项权利要求所述的方法模制风力涡轮机叶片(1)的过程中根据权利要求9-10中任一项权利要求所述的膜(3)的使用。
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ITTO20080232A1 (it) | 2008-03-27 | 2009-09-28 | Alenia Aeronautica Spa | Procedimento di fabbricazione di un elemento strutturale allungato in materiale composito tramite formatura e cura in autoclave con sacco a vuoto |
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2010
- 2010-05-20 EP EP10163393.1A patent/EP2388131B1/en not_active Not-in-force
- 2010-05-20 DK DK10163393.1T patent/DK2388131T3/en active
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2011
- 2011-04-22 US US13/092,193 patent/US9005381B2/en not_active Expired - Fee Related
- 2011-05-18 CA CA2740478A patent/CA2740478A1/en not_active Abandoned
- 2011-05-18 NZ NZ592931A patent/NZ592931A/xx not_active IP Right Cessation
- 2011-05-20 BR BRPI1102261-2A patent/BRPI1102261A2/pt not_active Application Discontinuation
- 2011-05-20 KR KR1020110048094A patent/KR20110128159A/ko not_active Application Discontinuation
- 2011-05-20 CN CN201110131839.5A patent/CN102248687B/zh not_active Expired - Fee Related
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2015
- 2015-02-19 US US14/626,125 patent/US20150166748A1/en not_active Abandoned
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EP1310351A1 (en) * | 2001-11-13 | 2003-05-14 | Bonus Energy A/S | Method for manufacturing windmill blades |
CN101462360A (zh) * | 2007-12-18 | 2009-06-24 | 上海玻璃钢研究院 | 大功率风力机叶片根端一次性真空辅助灌注成型方法 |
CN101618606A (zh) * | 2008-04-30 | 2010-01-06 | Bha控股公司 | 制造风力涡轮机转子叶片的方法 |
CN101590698A (zh) * | 2008-05-05 | 2009-12-02 | 西门子公司 | 包括复合材料的风轮机叶片的制造方法 |
Also Published As
Publication number | Publication date |
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DK2388131T3 (en) | 2016-12-19 |
US9005381B2 (en) | 2015-04-14 |
NZ592931A (en) | 2012-08-31 |
CN102248687A (zh) | 2011-11-23 |
KR20110128159A (ko) | 2011-11-28 |
EP2388131B1 (en) | 2016-08-31 |
CA2740478A1 (en) | 2011-11-20 |
BRPI1102261A2 (pt) | 2012-12-25 |
EP2388131A1 (en) | 2011-11-23 |
US20110284150A1 (en) | 2011-11-24 |
US20150166748A1 (en) | 2015-06-18 |
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