CN102448711A - 受防护的风力涡轮叶片、制造其的方法及风力涡轮 - Google Patents
受防护的风力涡轮叶片、制造其的方法及风力涡轮 Download PDFInfo
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Abstract
本发明涉及一种受防护的涡轮叶片(100)，所述涡轮叶片包括第一涡轮叶片壳体(201)和第二涡轮叶片壳体(202)，所述涡轮叶片壳体是由固化树脂(205)连接的纤维增强的涡轮叶片壳体，并且在涡轮叶片的前缘处设有防护盖(105)以用于防护在涡轮叶片的前缘处(103)的固化树脂免于腐蚀。根据本发明，防护盖是包括抗UV的热塑材料层和固化环氧树脂层的复合物，所述抗UV的热塑材料具有以下特性：表面自由能小于35mJ/m2，和耐腐蚀性大于连接所述涡轮叶片壳体的固化树脂的耐腐蚀性，其中，固化环氧树脂层覆盖用于在涡轮叶片的远侧半部的至少部分长度上连接第一和第二叶片壳体的固化树脂，并且粘结到所述涡轮叶片。
Description
技术领域
本发明涉及一种受防护的涡轮叶片，其包括第一涡轮叶片壳体和第二涡轮叶片壳体，所述涡轮叶片壳体是由固化的树脂连接的纤维增强的涡轮叶片壳体，并且在涡轮叶片的前缘处设有防护盖，以用于防护涡轮叶片的前缘处的固化的树脂免于腐蚀。
背景技术
这样受防护的涡轮叶片从US2008/181775可知，该文献公开在其前缘处具有含金属的盖的涡轮叶片。为了防止由于结冰产生的问题，特别是不平衡的问题和/或叶片丧失符合空气动力学的最佳形状的问题，存在有加热元件。
发明内容
本发明的目的是提供一种风力涡轮叶片，所述风力涡轮叶片在没有加热元件的情况下、或者如果有加热元件在加热元件失效的情况下维持良好的空气动力学特性。
至此，根据本发明的风力涡轮叶片的特征在于：防护盖是包括抗UV热塑材料层和固化环氧树脂层的复合物，所述抗UV热塑材料具有以下特性：
-表面自由能小于35mJ/m2，和
-耐腐蚀性大于连接涡轮叶片壳体的固化树脂的耐腐蚀性，
其中，固化环氧树脂层覆盖用于在涡轮叶片的远侧半部的至少部分长度上连接第一和第二叶片壳体的固化树脂，并且粘结到所述涡轮叶片上。
热塑材料层的性质减小在其表面上积聚冰的机会，由此维持涡轮叶片的符合空气动力学的形状，并且防止由于冰引起的风力涡轮的不平衡，以及防护连接叶片壳体的固化树脂。术语“抗UV”既指固有的抗UV性，或指通过存在用于稳定UV的添加剂所获得的抗性。热塑材料优选地具有至少5倍于用于连接叶片壳体的固化树脂的抗性。耐腐蚀性将利用在示例部分中描述的使用人造雨的方法进行测量。热塑材料层的厚度大体上为0.2至10mm，优选为0.3至3mm，更优选为0.5至1mm。涡轮叶片的远侧半部是指远离根部并且包括涡轮叶片的顶端的半部。当提及固化环氧树脂层粘结到所述涡轮叶片时，这是指该固化环氧树脂层面对涡轮叶片壳体并且大体上用环氧树脂粘结到所述涡轮叶片壳体，如在以下示例中将详细描述的那样。
根据一个优选实施例，抗UV热塑材料包括对UV稳定的聚烯烃。
该材料在耐腐蚀性和表面自由能方面显示出良好的品质。直链聚烯烃是优选的，这是因为它们具有更高的密度和耐腐蚀性。
根据一个优选实施例，聚烯烃是超高分子量的聚乙烯，并且更优选为超高分子量的聚丙烯、聚乙烯和聚丙烯的共聚物或者包括聚乙烯和聚丙烯的混合物。
特别地，聚丙烯显示出良好的耐腐蚀性和较低的表面自由能。聚丙烯在性质上还已具有更强的UV抗性。共聚物和混合物还优选地具有超高分子量。
根据一个优选实施例，固化环氧树脂层为纤维增强的固化环氧树脂层，所述纤维部分地嵌在固化环氧树脂中且部分地嵌在防护盖的其余部分。
这样的防护盖非常坚固。为了最佳强度，优选的是纤维是包括纤维束的部分织物。
本发明还涉及一种用于制造根据本发明的风力涡轮叶片的方法，其中：
-抗UV热塑材料在模具中加热直至其软化为止，
-包括纤维束的织物放置在热塑材料一侧的顶部上的一侧浸入所述软化的热塑材料中，
-冷却设有包括纤维束的织物的热塑材料；
-设有包括纤维束的织物的热塑材料的织物的第二侧浸入可固化树脂中，并且可固化树脂被固化以生成固化环氧树脂层，
以生成成形的复合材料盖，之后
-可固化树脂应用到以下中的至少一者上：i)涡轮叶片的远侧半部的至少部分长度和ii)包括固化的环氧树脂的成形的盖的一侧；
-成形的盖放置在涡轮叶片组件的前缘的远侧半部的至少部分长度上，以使得所述固化树脂在涡轮叶片的远侧半部的至少部分长度上由成形的盖覆盖，所述涡轮叶片组件包括由固化的树脂连接的两个涡轮叶片壳体，和
-成形的盖通过固化可固化树脂粘结到所述涡轮叶片组件上；
以生成受防护的涡轮叶片。
由于使用模具，受防护的涡轮叶片的形状能够非常好地得到控制，从而使其在空气动力学上更适合，并且由此较少经受腐蚀。纤维毡例如通过使用闭式模具将其压入热塑材料中，用其所述一侧嵌在热塑材料中。在软化的热塑树脂的上下文中，术语嵌入和浸入是完全可以互换的。固化环氧树脂层面对涡轮叶片壳体，并且抗UV热塑材料当前形成前缘且受环境(大气)影响。
根据一个优选实施例，当固化可固化树脂以生成成形的盖的固化环氧树脂层时，在与包含织物的浸入纤维束的一侧相反的可固化树脂一侧处，存在起纹理的剥离层(peel ply)以提供增大的表面面积的粗糙表面，从而增大成形的盖和涡轮叶片之间的粘结强度。
最后，本发明涉及风力涡轮，所述风力涡轮包括至少一个根据本发明的涡轮叶片或使用根据本发明的方法制造的涡轮叶片。
附图说明
本发明将参考附图进行说明，其中：
图1示出在其前缘处设有防护盖的涡轮叶片；和
图2示出沿II-II穿过图1的涡轮叶片的示意性剖视图。
具体实施方式
图1示出涡轮叶片100，所述涡轮叶片100具有根部101、顶端102、前缘103和后缘104。在前缘103处设有防护盖105。
图2示出沿图1的II-II线的剖视图，显示涡轮叶片100包括第一涡轮壳体201和第二涡轮壳体202。第一涡轮壳体201和第二涡轮壳体202用固化的树脂205连接。涡轮叶片201和202具有凹进区域211、212，以使得防护盖105无缝地联接，并且防护盖105的外表面和涡轮叶片壳体201、202限定涡轮叶片100的符合空气动力学的轮廓。
防护盖105保护涡轮叶片100的前缘103以及特别是固化树脂。防护盖105包括HMWPE层301(0.5mm的厚度)、市场上有售的玻璃纤维毡302(800gsm双轴+/-45°非卷曲织物)，所述玻璃纤维毡302部分地嵌在所述HMWPE层301中，从而在诸如真空模具的模具中加热HMWPE层301。玻璃纤维毡302的突出纤维用环氧树脂浸染并并随后固化以生成固化的环氧树脂层303。防护盖105的整个厚度为2.5mm。环氧树脂303与用于制造叶片壳体201、202的大体上为相同的类型，并且特别是常规用于使用树脂注塑成型法(RIM)制造风力涡轮叶片的树脂。用于RIM的典型树脂为利用例如在75℃加热进行固化的环氧树脂。为了提升防护盖105附接至涡轮壳体201、202的强度，待形成层303的未固化的环氧树脂有利地用尼龙层片(nylonply sheet)覆盖，所述尼龙层片本身是已知的。就在防护盖105附接至包含叶片壳体201、202(所述叶片壳体201、202利用固化的树脂彼此相连)的单元之前去除掉该层片。利用可加热固化的环氧树脂304实现防护盖105到该单元的粘结，所述环氧树脂304又优选地与用于层303的环氧树脂是相同的。
腐蚀测量
用于测试材料的耐腐蚀性的方法已知用于测试航空器机翼或导弹。这被称为雨蚀测试，并且被用于确定用于根据本发明的叶片的防护盖的耐腐蚀性。
耐腐蚀性通过使样品经历人造雨(雨滴具有2mm的直径)在腔室内进行测量。样品围绕竖直轴线进行旋转，并且样品以136.6m/s的速度运动。人造雨量为每平方米25l/hr，并且其从距样品30cm的高度落下。腔室内的其他条件为：
-相对湿度＞99％。
-温度(在测试期间由于释放热量会发生变化)：18.8℃-27.1℃。
样品在距旋转中心轴线1m处进行旋转，并且具有以下尺寸：6cm的宽度、抛物线形以模拟前缘、前高20mm。利用显微镜以规定的时间间隔可视检查样品的腐蚀。使用两种量度：
-无损害的时间；以及
-每时间单位的重量损失。
初始重量为42.8878g。在270分钟后，重量为42.8846，重量损失仅为0.0032g，这是非常让人满意的。可视检查显示表面粗糙度随时间增加，但是没有碎屑。在270分钟后，粗糙度仍非常小。
冰实验
为了研究在结冰情况下的性能，进行以下实验。带有水的盘在冷冻器中冰冻至-24℃。上表面冰溶化并且由聚乙烯(60×80mm)制成具有小于35mJ/m2表面自由能的板被放置在剩余冰顶部上的水层中。盘被再次放入冰冻器中。需要从该盘去除该板的作用力(沿垂直于冰表面的方向)为30N。在类似的实验中，板被稍微弯曲并且强制移除冰，作用力显著变小。在两种情况下，板从冰上干净地分离，即没有冰留在表面上。
第二个实验包括将一滴冰水放置在从冰冻器取出由聚乙烯制成的板上。水滴凝固且通过弯曲该板非常容易地被移除掉。
这些实验提供了以下很好的指示：在实际情况中(即在旋转叶片的顶部上)，条件使得可能在防护盖上形成的任何冰都将被容易地移除掉。假如因为风速变化、叶片穿过塔或者归因于风速在各种高度处的差异，风速上的变化会导致叶片弯曲，从而去除冰。如果期望的话，叶片间距(pitch)可以改变以影响叶片的曲率。
Claims (7)
1.一种受防护的涡轮叶片，所述涡轮叶片包括第一涡轮叶片壳体和第二涡轮叶片壳体，所述第一涡轮叶片壳体和第二涡轮叶片壳体是由固化的树脂连接的纤维增强的涡轮叶片壳体，并且在所述涡轮叶片的前缘处设有防护盖以用于防护在所述涡轮叶片的前缘处的固化的树脂免于腐蚀，其特征在于，所述防护盖是包括抗UV的热塑材料层和固化的环氧树脂层的复合物，所述抗UV的热塑材料具有以下特性：
-表面自由能小于35mJ/m2，和
-耐腐蚀性大于连接所述第一涡轮叶片壳体和第二涡轮叶片壳体的固化的树脂的耐腐蚀性，
其中，所述固化的环氧树脂层覆盖用于在所述涡轮叶片的远侧半部的至少部分长度上连接所述第一涡轮叶片壳体和第二涡轮叶片壳体的固化的树脂，并且粘结到所述涡轮叶片。
2.根据权利要求1所述的受防护的涡轮叶片，其中，所述抗UV的热塑材料是对UV稳定的聚烯烃。
3.根据权利要求2所述的受防护的涡轮叶片，其中，所述聚烯烃是超高分子量的聚乙烯、超高分子量的聚丙烯、或聚乙烯和聚丙烯的共聚物、或包括聚乙烯和聚丙烯的混合物。
4.根据以上权利要求中任一项所述的受防护的涡轮叶片，其中，所述固化的环氧树脂层是纤维增强的固化的环氧树脂层，所述纤维部分地嵌在固化的环氧树脂中且部分地嵌在所述复合物的其余部分。
5.一种用于制造根据以上权利要求中任一项的风力涡轮叶片的方法，其中：
-抗UV的热塑材料在模具中加热直到所述热塑材料软化为止，
-包括纤维束的织物放置在所述热塑材料一侧的顶部上的一侧浸入所述软化的热塑材料中，
-冷却设有包括纤维束的织物的热塑材料；
-设有包括纤维束的织物的热塑材料的织物的第二侧浸入可固化树脂中，并且所述可固化树脂被固化以生成固化的环氧树脂层，
以生成复合材料的成形的盖，之后
-可固化树脂应用到以下中的至少一者上：i)所述涡轮叶片的远侧半部的至少部分长度和ii)包括固化的环氧树脂的成形的盖的一侧；
-所述成形的盖放置在涡轮叶片组件的前缘的远侧半部的至少部分长度上，以使得所述固化的树脂在所述涡轮叶片的远侧半部的至少部分长度上由所述成形的盖覆盖，所述涡轮叶片组件包括由固化的树脂连接的两个涡轮叶片壳体，和
-所述成形的盖通过固化可固化树脂粘结到所述涡轮叶片组件上；
以生成所述受防护的涡轮叶片。
6.根据权利要求5所述的方法，其中，当固化所述可固化树脂以生成所述成形的盖的固化的环氧树脂层时，在与包含所述织物的浸入的纤维束的一侧相反的可固化树脂一侧处，存在起纹理的剥离层以提供增大的表面面积的粗糙表面，从而增大所述成形的盖和所述涡轮叶片之间的粘结强度。
7.一种风力涡轮，所述风力涡轮包括至少一个根据权利要求1至4中任一项所述的涡轮叶片或者使用根据权利要求5或6所述的方法制造的涡轮叶片。
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| PCT/NL2010/000064 WO2010117262A1 (en) | 2009-04-10 | 2010-04-09 | A protected wind turbine blade, a method of manufacturing it and a wind turbine |
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| CN105934327A (zh) * | 2013-08-01 | 2016-09-07 | 叶片动力学有限公司 | 耐腐蚀空气动力整流件 |
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Also Published As
| Publication number | Publication date |
|---|---|
| EP2416950A1 (en) | 2012-02-15 |
| US20120034094A1 (en) | 2012-02-09 |
| US8961142B2 (en) | 2015-02-24 |
| EP2416950B1 (en) | 2013-09-25 |
| WO2010117262A1 (en) | 2010-10-14 |
| CN102448711B (zh) | 2015-05-13 |
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