CN102310569A - 用于制造工件的铸造方法 - Google Patents

用于制造工件的铸造方法 Download PDF

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CN102310569A
CN102310569A CN201110180958XA CN201110180958A CN102310569A CN 102310569 A CN102310569 A CN 102310569A CN 201110180958X A CN201110180958X A CN 201110180958XA CN 201110180958 A CN201110180958 A CN 201110180958A CN 102310569 A CN102310569 A CN 102310569A
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K.席布斯拜
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Abstract

本发明涉及用于制造工件的铸造方法。该方法包括步骤：在模具（1，2）内准备玻璃纤维（4）；围绕所述玻璃纤维（4）准备闭合模具腔（7）；使用无氧气体冲灌所述闭合模具腔（7）；将树脂注射到所述闭合模具腔（7）内；以及固化被浇铸的工件。此外，描述了通过本发明的方法来制造的工件。

Description

用于制造工件的铸造方法
技术领域
本发明涉及用于制造工件的方法，具体地涉及制造风力涡轮机转子叶片的方法。还涉及工件，例如风力涡轮机转子叶片。
背景技术
大量工件，特别是包括层压结构的工件，例如风力涡轮机转子叶片，通常通过将树脂浇铸到具有玻璃纤维叠层的闭合模具内来制造。能够被用于制造例如风力涡轮机转子叶片的工件的一种树脂是聚酯树脂。聚酯树脂是一种能够被用于玻璃纤维叠层以便风力涡轮机转子叶片生产的非常易浇铸的树脂。通过添加一定量催化剂来控制树脂的固化时间。不过，涉及聚酯树脂使用的一个难点在于这种树脂具有非常难闻的气味，对于新铸件和所用的工作空间而言也是如此。
发明内容
因此，本发明的第一目的是提供减轻上述难点的用于制造工件的方法。本发明的第二目的是提供减轻前述难点的工件。
第一目的是通过如权利要求1所述的用于制造工件的方法来实现的。第二目的是通过如权利要求13所述的工件来实现的。从属权利要求限定了本发明的进一步改进。
本发明的用于制造工件的方法包括如下步骤：在模具中准备玻璃纤维，围绕玻璃纤维准备闭合模具腔，使用无氧气体冲灌闭合模具腔，将树脂注射到闭合模具腔内以及固化被浇铸的工件。
本发明的方法基本上克服了现有技术铸造的所述难点，特别是克服了使用聚酯树脂铸造的现有技术的难点。
有利地，可以在将树脂注射到闭合模具腔内之前实现使用无氧气体冲灌闭合模具腔的步骤。在注射树脂之前，例如注射聚酯树脂之前，使用无氧气体冲灌所述腔导致了被铸造工件不会很难闻。至少，显著地减少了难闻气味。如果在注射树脂，具体是注射聚酯树脂期间以及固化期间存在氧的话，则会产生难闻气味。此外，本发明的铸造方法具有积极的副作用，即铸件的表面，例如被铸造的转子叶片的表面，获得了更好的固化。
例如，在模具内准备玻璃纤维的步骤可以包括将多个玻璃纤维层放置在模具内。此外，除玻璃纤维之外的其他材料的附加层能够被置于模具内，例如用于增加工件的稳定性。优选地，工件可以是风力涡轮机转子叶片。
所用的用于冲灌闭合模具腔的无氧气体能够有利地是非活性气体，这意味着其具有降低的化学反应性。优选地，能够使用惰性气体，例如氮气，来冲灌闭合模具腔。
闭合模具腔（内的空气）可以例如完全由无氧气体所代替。这会有效地减少闭合模具腔内的气体和被注射树脂之间的化学反应。因此，减少了被铸造工件的难闻气味。
在使用无氧气体冲灌期间，在闭合模具腔内部的气体（例如空气）离开闭合模具腔。能够监控在使用无氧气体冲灌期间离开闭合模具腔的气体中的氧浓度。闭合模具腔能够包括用于在使用无氧气体冲灌期间离开闭合模具腔的气体的出口。优选地，在这个出口处监控氧浓度。有利地，通过氧含量监控器来监控氧浓度。
优选地，使用无氧气体冲灌闭合模具腔直到在使用无氧气体冲灌期间离开闭合模具腔的气体中的氧浓度低于预定值。有利地，冲灌闭合模具腔直到离开气体中的氧被全部去除。
树脂，特别是包括苯乙烯的树脂，例如聚酯树脂和/或乙烯酯树脂，能够被注射到闭合模具腔内。大体而言，能够通过添加催化剂来控制树脂的固化时间。
通过上述方法来制造本发明的工件。本发明的工件具有与上述本发明方法相同的优点，具体地被铸造工件不难闻或者至少显著地减少了其难闻气味。
本发明的工件可以包括任意树脂，特别是包括苯乙烯的树脂。例如其可以包括聚酯和/或乙烯酯，特别是被固化的聚酯树脂和/或被固化的乙烯酯树脂。优选地，工件是风力涡轮机转子叶片。
结合附图从实施例的下述描述中将显而易见到本发明的其他特征、性质和优点。大体而言，所有所述特征在单独地和彼此结合使用的情况下均是有利的。
附图说明
图1示意性示出了用于制造风力涡轮机转子叶片的闭合模具的截面图。
图2示意性示出了在冲灌过程期间用于制造风力涡轮机转子叶片的闭合模具的截面图。
具体实施方式
现在将参考图1和图2描述本发明的实施例。图中物体的尺寸为了清楚的目的被选择并且不必须反映相对尺寸。
图1示意性地示出了用于制造风力涡轮机转子叶片的闭合模具的截面图。为了制造风力涡轮机转子叶片，玻璃纤维，优选地多个玻璃纤维层4被准备在模具中。模具包括上模具元件1、下模具元件2和芯元件3。
首先，多个玻璃纤维层4被铺置到下模具元件2内。之后，芯元件3被铺置于下模具元件2内的玻璃纤维层4上。之后，多个玻璃纤维层4被铺置到芯元件3上并且围绕芯元件3被准备。然后，通过将上部元件1装配到下模具元件2上来闭合模具。
包括下模具元件2和上模具元件1的闭合模具包括内腔7。内腔7填充有空气。此外，闭合模具包括入口孔5和出口孔6。
图2以截面图形式示意性示出了冲灌过程期间的模具。在图2中，入口孔5被用于将无氧气体注射到内腔7中，该无氧气体具体的是惰性气体，例如氮气。被注射气体的流动方向由箭头8指出。内腔7内的空气通过出口6被冲离内腔7。离开内腔7的气体的流动方向由箭头9指出。通过使用无氧气体（例如氮气）冲灌闭合模具腔，确保了闭合模具腔7内的基本所有空气均被被注射气体（例如氮气）所代替。
氧含量监控器10位于出口6处。当使用无氧气体冲灌闭合模具腔时，闭合模具的出口6被氧含量监控器10监控。因而，监控了被冲离空气内的氧水平。优选地，冲灌所述腔7直到氧被全部去除或者低于预定水平。这可以优选地通过测量沿流动方向9离开出口6的气体中的氧浓度来实现。
在使用例如氮气冲灌闭合模具腔之后，树脂被注射到闭合模具腔7内。所用树脂能够包括苯乙烯。其能够优选地是聚酯树脂。可替换地，乙烯酯树脂能够被注射到闭合模具腔7内。然后，被浇铸的结构被固化。
由于在其注射或固化期间被注射树脂不与氧或任意其他化学反应气体接触，所以被铸造的结构或工件（例如被制造的风力涡轮机转子叶片）不会难闻。至少其难闻气味被显著减少。此外，所述铸造方法具有如下积极的副作用，即被铸造工件（例如风力涡轮机转子叶片）的表面被更好地固化。
此外，能够通过添加一定量的催化剂来控制树脂的固化时间。

Claims (15)

1.一种用于制造工件的方法，包括步骤：
-在模具（1，2）内准备玻璃纤维（4），
-围绕所述玻璃纤维（4）准备闭合模具腔（7），
-使用无氧气体冲灌所述闭合模具腔（7），
-将树脂注射到所述闭合模具腔（7）内，以及
-固化被浇铸的工件。
2.根据权利要求1所述的方法，其中
多个玻璃纤维层（4）被置于所述模具（1，2）内。
3.根据权利要求1或2所述的方法，其中
所述工件是风力涡轮机转子叶片。
4.根据权利要求1-3中任一项所述的方法，其中
所述闭合模具腔（7）被惰性气体冲灌。
5.根据权利要求4所述的方法，其中
所述闭合模具腔（7）被氮气冲灌。
6.根据权利要求1-5中任一项所述的方法，其中
所述闭合模具腔（7）内的空气完全由所述无氧气体所代替。
7.根据权利要求1-6中任一项所述的方法，其中
在使用所述无氧气体冲灌期间离开所述闭合模具腔（7）的气体中的氧浓度被监控。
8.根据权利要求7所述的方法，其中
所述闭合模具腔（7）包括用于在使用所述无氧气体冲灌期间离开所述闭合模具腔（7）的气体的出口（6），并且在所述出口（6）处监控氧浓度。
9.根据权利要求7或8所述的方法，其中
所述氧浓度由氧含量监控器（10）来监控。
10.根据权利要求1-9中任一项所述的方法，其中
使用所述无氧气体冲灌所述闭合模具腔（7）直到在使用所述无氧气体冲灌期间离开所述闭合模具腔的气体中的氧浓度低于预定值。
11.根据权利要求1-10中任一项所述的方法，其中
包括苯乙烯的树脂被注射到所述闭合模具腔（7）内。
12.根据权利要求1-11中任一项所述的方法，其中
所述树脂的固化时间通过添加催化剂来控制。
13.一种通过如权利要求1-12中任一项所述的方法制造的工件。
14.根据权利要求13所述的工件，其中
所述工件包含包括苯乙烯的树脂。
15.根据权利要求13或14所述的工件，其中
所述工件是风力涡轮机转子叶片。
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