CN102325646A - 通过嵌入预固化纤维增强树脂层制造风轮机叶片的方法 - Google Patents

通过嵌入预固化纤维增强树脂层制造风轮机叶片的方法 Download PDF

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CN102325646A
CN102325646A CN2010800088690A CN201080008869A CN102325646A CN 102325646 A CN102325646 A CN 102325646A CN 2010800088690 A CN2010800088690 A CN 2010800088690A CN 201080008869 A CN201080008869 A CN 201080008869A CN 102325646 A CN102325646 A CN 102325646A
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wind turbine
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A·贝克
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Vestas Wind Systems AS
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Abstract

本发明涉及一种制造风轮机叶片或风轮机叶片的部件的方法。该方法包括：以至少部分重叠的关系布置至少一层未固化树脂预浸渍纤维(称为预浸渍坯)和至少一层已固化纤维增强树脂；以及固化包括未固化树脂的所述至少一层的树脂。所述至少一层已固化纤维增强树脂在放置于模塑表面上之前与至少一层未固化树脂预浸渍纤维组装在一起。该方法可例如用来制造风轮机叶片外壳元件或风轮机叶片主梁元件。本发明还涉及一种用于风轮机叶片中的预制坯，该预制坯包括处于至少部分重叠关系的至少一层未固化树脂预浸渍纤维和至少一层已固化纤维增强树脂。

Description

通过嵌入预固化纤维增强树脂层制造风轮机叶片的方法
技术领域
本发明涉及一种制造风轮机叶片或风轮机叶片的部件的方法，并且尤其涉及一种包括使用树脂预浸渍纤维层的制造方法。
背景技术
风轮机叶片及其部件通常由称为预浸渍坯的树脂预浸渍纤维层制造，树脂预浸渍纤维层布置于模型表面上并且经受真空和热以引起树脂的熔融或软化，随后对其进行固化(cure)。
关于使用预浸渍坯的一个缺点在于材料通常卷曲地输送，并且材料的形状保持性会在敷层(lay-up)过程期间由于形成纤维的折皱而引起问题。在产品厚度较大的情况下尤其如此，下层中的折皱甚至比由各个层的形状保持性单独所引起的折皱更恶化上层中的扭曲。
而且，预浸渍坯仅具有有限的侧向稳定性，并且必须小心以避免在敷层期间纤维的失准。在较大尺寸的预浸渍坯在一个工作表面上切割为期望形状并且随后不得不移动并布置于模型表面上时，预浸渍坯的操纵会特别困难。
另一个缺点在于固化是发热过程并且因此可导致最终产品中不利的内生热应力和变形，尤其对于具有较大厚度的产品。与发热固化过程相关的又一个缺点在于热可引起材料性能退化，其不能经受在固化过程期间升高的实际温度。
因此，改进的制造方法将是有利的，并且尤其是克服上述缺点的制造方法将是有利的。
发明内容
本发明的一个目标是提供一种由预浸渍坯制造风轮机叶片或风轮机叶片的部件的方法，通过该方法，在树脂固化期间整个给定截面的平均温度增大低于相应已知方法。
本发明的另一个目标是提供一种由预浸渍坯制造风轮机叶片或风轮机叶片的部件的方法，通过该方法，与相应已知方法相比，能更容易防止纤维在敷层过程期间的失准。这种失准会出现在被制造元件的厚度方向上和侧向上。
本发明的另一个目标是提供一种由预浸渍坯制造风轮机叶片或风轮机叶片的部件的方法，通过该方法，更容易在敷层过程期间操纵各层。
本发明的又一目标是提供对于现有技术的一种替代方案。
因而，上述目标和几个其他目标将在本发明的第一方面通过提供一种制造风轮机叶片或风轮机叶片的部件的方法来获得，该方法包括：
—以至少部分重叠的关系布置至少一层未固化树脂预浸渍纤维和至少一层已固化纤维增强树脂；以及
—固化包含未固化树脂的所述至少一层中的所述树脂，其中所述至少一层已固化纤维增强树脂在放置于模塑表面上之前与至少一层未固化树脂预浸渍纤维组装在一起。
“已固化”优选地意味着已完全固化。
通过所述层的这种预组装，材料可以由于由所述已固化层引起的较大刚性而更易于操纵，并且因为所述未固化层的纤维至少部分地由所述已固化层支撑因此更易于避免纤维的失准。这在较大尺寸的层在一个工作表面处切割为期望形状并且随后必须移动并且布置于模塑表面上时是特别有利的。这种预组装的层在下文被称为预制坯(pre-form)；它们还可以称为板坯(slabs)。
与未固化层相比具有更大刚性的已固化层的结合还抑制了未固化材料交付卷筒由于材料的形状保持性而形成折皱的倾向。
在本发明的一个实施例中，已固化纤维增强树脂层布置于每层树脂预浸渍纤维的两侧上，这使得更易于在敷层期间操纵材料而无需接触未固化树脂。而且，已固化层不像未固化层那样粘着，因此变得更容易将层推压至期望的相互位置同时将预制坯布置于模塑表面上。替代地，多层树脂预浸渍纤维布置为彼此叠置，并且已固化纤维增强树脂层布置于树脂预浸渍层的每个外层的外表面上。
在本发明的另一个实施例中，未固化树脂预浸渍纤维层布置于每个已固化纤维增强树脂层的两侧上。因此，未固化树脂的粘合效果可使得更易于确保层在敷层过程期间保持就位。
在另一个实施例中，所述层布置为使得所述组装后的层的一个外侧表面包括已固化树脂，并且另一个外表面包括未固化树脂。因此，能获得上述后两个实施例之间的折衷。所述未固化树脂能作为粘合剂以保持所述层的相互位置。
该方法可还包括步骤：
—将所述至少一层树脂预浸渍纤维和所述至少一层已固化纤维增强树脂放置在模塑表面上，
—在所述至少一层树脂预浸渍纤维和所述至少一层已固化纤维增强树脂上方提供气密且柔软的封罩，
—基本上排出存在于所述封罩中的空气，以及
—加热所述封罩中的所述层预定的时间。
因此仅需要一个模塑表面，并且所制造元件的厚度能简单地通过改变所使用层的数量来调节。
在本发明的一些实施例中，所述层的所述组装可包括在所述层上施加压力的步骤。因此，获得更强的粘合力。
这种压力可通过使用至少一个辊来施加。一个辊可与平面或与一个或多个其他辊组合使用。所述至少一个辊还可用来移动所述材料，或所述移动可通过其他拉动或推动装置实现。
每层的厚度可在0.3和2毫米之间，比如在0.3和0.5毫米之间，或在0.5和1毫米之间，或在1和2毫米之间。在一些实施例中，所述至少一层树脂预浸渍纤维和所述至少一层已固化纤维增强树脂在组装之前具有基本上相同的厚度。
所述纤维可单向地布置，但是任何纤维定向都视为由本发明的范围覆盖。所述纤维还可在更多的方向上布置和/或在每个或一些层内交织。
各层间的纤维定向也可以不同，例如，以便利用多层或者利用单向布置的纤维在若干个方向上获得纤维增强。
在本发明的一些实施例中，在所述至少一层树脂预浸渍纤维和所述至少一层已固化纤维增强树脂中所述树脂和/或纤维可以是相同类型的。因此，能避免机械性质的突然改变，这种突然改变会在加载期间引起应力集中。如果所述至少一层已固化纤维增强树脂通过固化其类型与用于复合材料剩余部分的类型相同的至少一层树脂预浸渍纤维来提供，例如可获得类似的性质。
所述至少一种树脂可选择自：环氧树脂、聚酯、乙烯基酯以及苯酚(phenol)。所述纤维例如可以是碳、玻璃或芳族聚酰胺纤维(aramidefiber)。
一种如上所述的方法可例如用来制造风轮机叶片外壳元件或风轮机叶片主梁元件(spar member)。其可例如用来制造风轮机外壳元件的后缘纵梁(stringer)或连接纵梁。
本发明的第二方面涉及由如上所述的方法制造的风轮机叶片外壳元件。
本发明的第三方面涉及由如上所述的方法制造的风轮机叶片主梁元件。
本发明的第四方面涉及一种用于风轮机叶片的预制坯，该预制坯包括处于至少部分重叠关系的至少一层未固化树脂预浸渍纤维和至少一层已固化纤维增强树脂，其中所述层以开始和结束于已固化层的顺序布置。因此能易于在无需接触未固化树脂的情况下操纵预制坯。
替代地，所述层以开始和结束于未固化层的顺序布置。因此，未固化树脂的粘合效果使得更易于确保层在敷层过程期间保持就位。
所述层能以开始于已固化层和结束于未固化层的顺序交替地布置，或反之亦然。因此，能获得所述后两个实施例之间的折衷。所述未固化树脂能作为粘合剂以使得所述层的相互位置得以保持。
预制坯优选地意味着预成形的纤维增强，其可在放置于模塑表面上之前形成为期望的形状和尺寸。这种已固化和未固化层的预制坯可便于在布置于模塑表面上期间材料的操纵。所述预制坯还可在平面上形成以在随后的步骤中获得最终的几何结构。
所述预制坯可包括多层未固化树脂预浸渍纤维层和多层已固化纤维增强树脂。然而，其还可包括仅一层的一种类型或两种类型。所述层可分别交替地布置为已固化的和未固化的，或反之亦然。
本发明的第一、第二、第三和第四方面可每个与任何其他方面相组合。本发明的这些以及其他方面将参照下述实施例变得明显并且阐述。
附图说明
根据本发明的制造复合元件的方法现在将结合附图更详细地进行描述。附图示出了实施本发明的一种方式并且不是要构造为限制于落入所附权利要求的范围内的其他可能实施例。
图1示意性地示出一种制造包括预固化材料层的复合元件的方法，
图2示意性地示出在已知预浸渍坯交付卷筒中的形状保持效果，
图3示意性地示出包括具有已固化和未固化树脂的预浸渍坯层的预制坯的层压结构，
图4示意性地示出一种提供图3中的预组装层的可能方式，
图5示意性地示出根据本发明的方法用于制造风轮机叶片外壳的后缘纵梁的应用，
图6示意性地示出在图5中的纵梁中的所述层的分解横截视图，并且
图7示意性地示出根据本发明的方法用于制造风轮机叶片外壳的连接纵梁的应用。
具体实施方式
通常用于制造风轮机涡轮叶片或其部件(比如叶片外壳)的制造方法是通过使用预浸渍坯。多个预浸渍坯布置为彼此叠置并且通过施加真空和热来固结(consolidate)。
在根据本发明的制造方法中，上述问题通过在复合元件中嵌入已固化材料来消除。这种已固化材料通常由其类型与用于复合元件剩余部分的类型相同或类似的一层或多层预浸渍坯制成。因此，能避免由于厚度上机械性质的突然改变而造成的应力集中。
在图1中示意性地示出了一种可能的制造方法。预定数量的未固化预浸渍坯1和一定数量的预固化纤维增强树脂层2(所述层都切割为期望形状)放置于模塑表面3上。在图1中示出了两层未固化预浸渍坯1之后是一层已固化材料2的叠置顺序。这两种类型的层示出为具有不同的厚度，这仅是为了示例性的目的。实际上，它们通常具有大致相同的厚度，通常在1至2毫米的量级。在替代实施例(未示出)中，所述层可布置为使得每个第三层或第四层是预固化的。然而，在本发明的范围内任何叠置顺序都是可能的。剥离层4a通常放置于层1、2的顶部上，以确保所制造元件的表面一直保持清洁直到可能的随后处理步骤。剥离层4a的顶部上通常是分离箔4b，比如多孔塑料箔，以及通气层4c。所有的层1、2、4a、4b、4c由气密且柔软的片材5覆盖，片材5通过使用密封带7密封至模塑表面3以提供封罩6，空气能从封罩6通过使用真空泵(未示出)经由真空端口(未示出)排出。在封罩6中存在的空气中的基本上所有气体都已经排出时，施加预定时间的热以引起所述预浸渍树脂的粘性下降，随后固化。压力还可与热组合地施加。固化条件确定为针对没有预固化层2的预浸渍坯1，同时考虑有利的较低热形成。所述条件将取决于所使用的材料以及所制造元件的尺寸。最佳固化条件例如可以是通过试验和/或计算机模拟来确定。
在一种替代的制造方法中，预制坯首先在固结台(也称为工作板)上制成，它们在该处敷层并且固结但是没有固化，通常通过使用真空，如上所述。这个固结步骤不是必须包括加热。预制坯如上所述随后布置于模塑表面上并且固化以获得最终的几何结构。预制坯将在下面进一步详细描述。
预固化层2将不再生热，但是相反地，将吸收由预浸渍坯1中的树脂的发热固化过程引起的一些热。与相同厚度但是完全由未固化预浸渍坯1制成的复合元件相比，这在固化期间引起较低的平均温度。预固化材料2和未固化材料1的实际相对量应当选择为确保温度的发展不会损害材料自身或相邻的材料。对于给定应用的层1、2的适当顺序和数量例如能通过试验和/或通过计算机模拟确定。
在图1中，模塑表面示出为平面，但是实际上其通常是弯曲的，比如具有双曲率。这是例如在该方法用来制造风轮机或风轮机叶片的部件时的情况。
树脂将通常是环氧树脂、聚酯、乙烯基酯和苯酚，但是用于预浸渍坯的任何树脂材料都由本发明覆盖。所述纤维例如可以是玻璃、碳或芳族聚酰胺。
与预浸渍坯1的使用相关的另一个问题在图2中示意性地示出。预浸渍坯1通常是交付卷筒，并且材料的形状保持性意味着其难以在敷层过程期间将预浸渍坯1保持就位，尤其对于较大厚度的复合元件。回卷的倾向可产生折皱，即，所述纤维的局部扭曲或者甚至断裂。这种局部缺陷会引起机械性质的下降，并且它们因此应当在质量控制期间显露并且能导致复合元件的报废。这些问题将很大程度上通过嵌入预固化并且因此刚性的层2来克服，因为这种层2将有助于抑制未固化预浸渍坯1的卷曲的倾向。预固化材料2也可以是交付卷筒，但是已经发现没有形状保持性。
预浸渍坯通常在一个工作表面处切割为期望的尺寸和形状并且随后，通常手工地移动并且布置于模塑表面上。所述未固化的预浸渍坯具有相对较低的刚性，这使得它们难以操纵，尤其对于较大的尺寸。在根据本发明的方法中，将至少一层已固化纤维增强树脂和至少一层未固化的树脂预浸渍纤维组装在一起，然后将它们放置于模塑表面上。因此，所述层的操纵能变得容易，因为不需要将未固化并且因此更柔软的层单独地从工作表面移动至模塑表面。因此获得平面中和平面外的更好稳定性，使得在敷层过程期间引起纤维失准的风险降低。
在本发明的一些实施例中，制造方法中的步骤包括在一层未固化的预浸渍坯1的每一侧将其与一层已固化的预浸渍坯2组装，如图3a中示意性地所示。这将产生外表面为已固化材料的预制坯8，其能在无需接触未固化材料的情况下操纵。这种材料还可由于非粘着外表面而更容易卷曲。替代地，至少一个所述外层可以是未固化材料，这使得其更易于保持布置为彼此叠置的两个预制坯的相互位置。这种预制坯的一个示例在图3b中示意性地示出。还能预接合超过三层。这些层可相对于已固化/未固化状态交替，或更多相同类型的层可布置为彼此叠置。预固化层2还可包括超过一层的纤维，比如由布置为彼此叠置的多个预浸渍坯制造。
未固化树脂的粘着效果可用来接合图3中示出的层1、2。一种包括使用辊9的可能接合过程的示例在图4中示意性地示出。已固化材料和未固化预浸渍坯示出为在卷筒10上输送，并且层通常在放置于另一个的顶部上之前切割为期望的形状。辊9能用来将压缩力P施加于此以在层1、2之间的界面两侧获得一定的结合强度。在经过辊9之后，预制坯8布置为彼此叠置以形成最终结构。这部分的过程通常相应于相对于图1描述的内容。使用辊9来接合所述层可以是替代使用真空或者是除了使用真空以外附加地使用。
如上所述，现有技术的潜在问题在于树脂的固化是发热过程，并且尤其对于较大的厚度，由固化材料发出的热将温度升高至高于炉温。这个温度增大可引起材料性能退化和/或在复合元件内形成热应力，这在使用期间是危险的，因为负荷承载能力降低。通过用预固化材料替代一些未固化预浸渍坯，能量释放材料(即最初未固化的材料)与能量吸收材料(即已固化的材料)之间的比率朝着更多吸收材料偏移。材料因此将在固化期间较少发热，使得工艺更快而不会带来材料性能退化并且因此降低复合元件机械性质的风险。
图5示意性地示出本发明的一个实施例，其中已固化层2嵌入风轮机叶片外壳半部12的后缘纵梁11中。两个这样的半部12随后胶合在一起以形成最终的叶片。用来构建纵梁11的层1、2通常沿着长度方向变细，根端部13处的最大宽度w在0.5米的数量级并且宽度w朝着顶端14以量级为20毫米每米的速度减少。尺寸与叶片的总长度相关，并且它们可与上面提到的叶片不同。在本发明的一个实施例中，减小宽度的层如图6中示意性地所示布置为彼此叠置，图6是图5中的纵梁11中的层1、2的分解横截图。宽度例如可从底层(相对于附图)的0.5米降低至顶层中的0.1米。在替代实施例(未示出)中，所述层交错地布置以使得获得菱形的横截面。所述层或敷层的其他可能几何形状对于本领域技术人员将是公知的。所述层能单独地布置，或者它们能预组装为预制坯8，如图3中所示。
所述用于后缘纵梁的方法还可用来制造如附图7中示意性地示出的连接纵梁15。
在上面的方法用来制造具有大曲率(并且尤其是双曲率)表面的复合元件时，所述层通常是呈带(未示出)的形式。利用已知的制造方法，所述纤维定向就容易扭曲，这可基本上通过如上所述使用预固化的层2来克服。所述带还可通过布置为一定程度重叠的连续层而保持就位。
虽然本发明已经结合具体实施例进行了描述，但是本发明不应当视为以任何方式限制于本示例。例如，如上所述预固化材料2的嵌入能用于风轮机叶片的几何结构中的任何位置处。本发明的范围由所附权利要求阐述。在权利要求的上下文中，词语“包括”并不排除其他可能的元件或步骤。而且，所涉及的指代比如“一”或“一个”等不应当视为排除多个。权利要求中关于附图所示元件的参考标号的使用也不应当视为限制本发明的范围。而且，不同权利要求中提及的各个特征也能有利地组合，并且不同权利要求中这些特征的叙述并不排除这些特征的组合是不可能的和有利的。

Claims (18)

1.一种制造风轮机叶片或风轮机叶片的部件的方法，该方法包括：
—以至少部分重叠的关系布置至少一层未固化树脂预浸渍纤维和至少一层已固化纤维增强树脂；以及
—固化包含未固化树脂的所述至少一层中的所述树脂，其中，在放置于模塑表面上之前，所述至少一层已固化纤维增强树脂与至少一层未固化树脂预浸渍纤维组装在一起。
2.根据权利要求1的方法，该方法还包括步骤：
—将所述至少一层树脂预浸渍纤维和所述至少一层已固化纤维增强树脂放置在模塑表面上，
—在所述至少一层树脂预浸渍纤维和所述至少一层已固化纤维增强树脂上方提供气密且柔软的封罩，
—基本上排出存在于所述封罩中的空气，以及
—对所述封罩中的所述层加热预定的时间。
3.根据权利要求1或2的方法，其中所述层的所述组装步骤包括在所述层上施加压力的步骤。
4.根据权利要求3的方法，其中所述压力通过使用至少一个辊来施加。
5.根据任一项前述权利要求所述的方法，其中每个层的厚度在0.3和2毫米之间，比如在0.3和0.5毫米之间，或在0.5和1毫米之间，或在1和2毫米之间。
6.根据任一项前述权利要求所述的方法，其中所述至少一层树脂预浸渍纤维和所述至少一层已固化纤维增强树脂在组装之前具有基本上相同的厚度。
7.根据任一项前述权利要求所述的方法，其中所述纤维单向地布置。
8.根据任一项前述权利要求所述的方法，其中在所述至少一层树脂预浸渍纤维和所述至少一层已固化纤维增强树脂中，所述树脂和/或纤维是相同类型的。
9.根据任一项前述权利要求所述的方法，其中所述至少一种树脂选择自环氧树脂、聚酯、乙烯基酯以及苯酚。
10.根据任一项前述权利要求所述的方法，其中该方法用来制造风轮机叶片外壳元件。
11.根据权利要求10的方法，其中该方法用来制造风轮机叶片外壳元件的后缘纵梁或连接纵梁。
12.根据权利要求1至9中任一项所述的方法，其中该方法用来制造风轮机叶片主梁元件。
13.一种利用根据权利要求10或11的方法制造的风轮机叶片外壳元件。
14.一种利用根据权利要求12的方法制造的风轮机叶片主梁元件。
15.一种在风轮机叶片中应用的预制坯，所述预制坯包括处于至少部分重叠关系的至少一层未固化树脂预浸渍纤维和至少一层已固化纤维增强树脂，其中各所述层以开始于已固化层和结束于已固化层的顺序布置。
16.一种在风轮机叶片中应用的预制坯，所述预制坯包括处于至少部分重叠关系的至少一层未固化树脂预浸渍纤维和至少一层已固化纤维增强树脂，其中各所述层以开始于未固化层和结束于未固化层的顺序布置。
17.根据权利要求15或16的预制坯，其中所述预制坯包括多层未固化树脂预浸渍纤维和多层已固化纤维增强树脂。
18.根据权利要求15至17中任一项所述的预制坯，其中所述层分别交替地布置为已固化的和未固化的，或反之亦然。
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