CN102753333A - 生产聚氨酯风轮机叶片的自动化方法 - Google Patents
生产聚氨酯风轮机叶片的自动化方法 Download PDFInfo
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- CN102753333A CN102753333A CN2010800397459A CN201080039745A CN102753333A CN 102753333 A CN102753333 A CN 102753333A CN 2010800397459 A CN2010800397459 A CN 2010800397459A CN 201080039745 A CN201080039745 A CN 201080039745A CN 102753333 A CN102753333 A CN 102753333A
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Abstract
本发明提供生产聚氨酯风轮机叶片和其它大物体的方法。本发明方法包括在风电场处形成用于聚氨酯风轮机叶片的模具,用自动化反应注塑(“RIM”)机将异氰酸酯和异氰酸酯活性组分注入模具中,闭合所述模具并对该模具进行加压和加热,使得所得聚氨酯固化,将聚氨酯叶片安装到风轮机中。或者,本发明方法包括在风电场处形成用于聚氨酯风轮机叶片的模具,用自动化长纤维注塑(“LFI”)机注入异氰酸酯、异氰酸酯活性组分和长纤维,闭合所述模具并对所述模具进行加压和加热,使得所得聚氨酯固化,将聚氨酯叶片安装到风轮机中。因为本发明的制造方法在风电场处进行,所以可以避免运输问题。
Description
技术领域
本发明一般涉及制造方法,更具体涉及原位生产风轮机叶片和其它大型物体的自动化方法。
发明背景
由于环保和政策方面的考虑,人们日益希望减少由进口化石燃料发电,因此设想风力在发电中的作用不断提高。美国能源部(U.S.Department ofEnergy(“DOE”))在2008年发表了题为“风能在2030年达到20%:在美国供电中增加风能的贡献(20%Wind Energy by 2030:Increasing Wind Energy′sContribution to U.S.Electricity Supply)”的报告,该报告调查了到2030年使用风能产生20%的国家电力需求的技术可行性。在全世界,多个国家已经利用风产生了大量电力。根据全球风能协会(Global Wind Energy Council(“GWEC”))发表的“2008年全球风能报告(Global Wind 2008 Report)”,西班牙目前在其电力需求中有11%来自风力,德国有约7.5%来自风力。欧盟的目标是到2020年在其电力中约35%来自可再生资源,其中约1/3是风能。
随着对风力发电能力要求的增加,发电机即风轮机的尺寸也要增大。风轮机叶片的尺寸和重量也相应地增加。较大的叶片(可能达到90米长或更长)难以制造,并且较重。而且,容纳该风轮机和支承叶片的塔也必须较大,因此更难以架设。因为这些较大的风轮机常常位于较遥远的区域,较大且较重的叶片的运输也成为问题。这些因素共同限制风力作为可行的可再生资源的全面应用。在本领域中,许多人试图解决与大叶片相关的问题,并取得了不同程度的成功。
例如,Lin等在美国公开专利申请第2006/225278号中揭示了一种两设施工艺,其中主要部件如根部和翼梁端在主设施中制造,次要的叶片部件如外壳在离风电场位置较近的次设施中制造,然后将主要部件和次要部件在风电场附近的组装地点组装。Llorente Gonzales等的美国公开专利申请第2008/0145231号显示在内部纵向加强结构的端部通过凸缘连接的风力叶片模块。轴向突出的突出部面对面相邻,具有排列的孔洞以接受连接螺钉、贯穿螺栓或铆钉,用于简便地在现场连接的模块。
Arelt的美国专利第7,334,989号描述了使用具有相应的楔形连接区域的顶部带和底部带,所述连接区域作用于连续的叶片段。在叶片段和连接带之间保留的空心空间被粘合剂注满,得到沿着主要的负载路径由多个嵌接/锥形连接形成的结合接头。Arelt还揭示了制造到连续的叶片段中的楔形连接区域,所述连续的叶片段利用相应的楔形连接区域与顶部带和底部带连接,从而在带和叶片连接区域之间的空心区域被注满粘合剂后沿着主要的负载路径形成结合锥形连接。
Moroz在美国专利第7,381,029号中提供了用于风轮机的多段叶片,该多段叶片包括在一端具有沥青轴承的毂延长器,具有贯穿其中的孔并安装在毂延长器上的裙部或整流罩,构造为与沥青轴承联接的外部。
因此,在本领域中需要用于风轮机叶片和其它大物体的改进的制造方法。该方法最大程度地减少或消除了现有技术方法中遇到的运输问题和叶片构造问题。
发明内容
因此,本发明提供生产聚氨酯风轮机叶片和其它大型物体的方法。本发明方法包括在风电场处或风电场附近形成用于风轮机叶片的模具,用自动化反应注塑(“RIM”)机将异氰酸酯和异氰酸酯活性组分注入该模具中,闭合该模具并对该模具进行加压和加热,使得所得聚氨酯固化,将聚氨酯叶片安装到风轮机中。而且,该方法包括在风电场处或风电场附近形成风轮机叶片模具,用自动化长纤维注塑(“LFI”)机注入异氰酸酯、异氰酸酯活性组分和长纤维,闭合该模具并对该模具进行加压和加热(或利用辐射,例如紫外光),使得所得聚氨酯固化,将聚氨酯叶片安装到风轮机中。因为本发明的制造方法在风电场处或风电场附近进行,所以可以避免运输问题。
通过以下本发明详述可以清楚地了解本发明的上述及其它优点和益处。
附图简要说明
出于说明而非限制性的目的,现在将结合附图描述本发明,其中:
图1显示模具和风轮机塔的自动化工艺的示意图;
图2显示风轮机塔底座的自动化工艺的例子;
图3显示生产大部件的自动化方法。
发明详述
现在出于说明而非限制的目的描述本发明。除非在操作实施例中或者另有说明,否则,说明书中使用的所有表示数量、百分量等的数字应理解为在所有情况中均受“约”字修饰。
本发明提供一种生产聚氨酯风轮机叶片的方法,该方法包括在风电场处或风电场附近形成用于风轮机叶片的模具,用自动化反应注塑(“RIM”)机将异氰酸酯和异氰酸酯活性组分注入该模具中,闭合该模具并对该模具进行加压和加热,使得所得聚氨酯固化,将聚氨酯叶片安装到风轮机中。较佳地,可使用辐射如紫外辐射使聚氨酯材料固化。
本发明还提供一种生产聚氨酯风轮机叶片的方法,该方法包括在风电场处或风电场附近形成风轮机叶片模具,用自动化长纤维注塑(“LFI”)机注入异氰酸酯、异氰酸酯活性组分和长纤维,闭合该模具并对该模具进行加压和加热,使得所得聚氨酯固化,将聚氨酯叶片安装到风轮机中。较佳地,使用辐射使得聚氨酯固化。
可通过以下方式在风电场处或风电场附近形成风轮机叶片模具:大规模快速原型操作,添加自动化制造(additive automated fabrication),或通过大规模快速原型操作制造风轮机叶片的正像,形成负像,铸造或模塑高强度复合件。该高强度复合件可包含金属、水泥和聚合物中的至少一种。
本发明方法可通过自动化反应注塑(“RIM”)法或自动化长纤维注塑(“LFI”)法产生风轮机叶片。
通过RIM技术生产聚氨酯模塑品是众所周知的,其描述参见例如美国专利第4,218,543号,其内容通过参考结合于此。RIM方法涉及一种填充模具的技术,通过该技术在非常短的时间内使用高输出量、高压计量设备将高活性液体起始组分在它们已经在所谓的“完全控制混合头”中混合后注入到模具中。在RIM方法中,将两个独立的物流充分混合,然后注入合适的模具中,但是可以使用超过两个的物流。第一物流含有多异氰酸酯组分,而第二物流含有异氰酸酯-活性组分和要包含的任何其它添加剂。在美国专利5,750,583、5,973,099、5,668,239和5,470,523中也详细描述了RIM法,这些专利文献的全部内容通过参考结合于此。
在LFI方法中,从混合头向开放模具进料,在该混合头中,由粗纱切割得到的玻璃纤维股束与聚氨酯反应混合物混合。可在混合头调节玻璃纤维的体积和长度。该方法使用较低成本的玻璃纤维粗纱,而不是使用垫子或预成形体。优选将玻璃粗纱加入配有玻璃切断装置的混合头。由于混合头设置在模具上并且混合头中的物质被分配到开放模具中,混合头在分配聚氨酯反应混合物的同时切断玻璃粗纱。当混合头中的物质已经被分配到模具中时,模具闭合,使反应混合物固化,从模具中移出复合物制品。模具优选保持在约120-190℉的温度。将混合头中的物质分配到模具中所需的时间一般在10-60秒之间。模具保持闭合的时间优选约为1.5-6分钟,以使玻璃纤维强化层固化。
在美国公开专利申请2005/0170189、2007/0098997、2004/0135280、2007/0160793和2008/0058468中描述了长纤维注塑,这些专利文献的全部内容通过参考结合于此。
可用于制造制品的热固性塑料材料和/或热塑性材料可任选地用选自下组的材料加强:连续玻璃纤维原丝,连续玻璃纤维毡,碳纤维,碳纤维毡,硼纤维,碳纳米管,金属薄片,聚酰胺纤维(例如KEVLAR聚酰胺纤维),和它们的混合物。如同本领域技术人员已知的,加强材料(特别是玻璃纤维)可在其表面上具有胶料,以提高它们对将引入它们的塑料的可混性和/或粘附性。在本发明中,玻璃纤维是优选的加强材料。如果使用加强材料(例如玻璃纤维),则加强材料优选以加强量存在于制品的热固性塑料材料和/或热塑性材料中,例如以制品的总重量为基准计,为5-75重量%。可用于本发明的长纤维的长度优选大于3毫米,更优选大于10毫米,最优选为12毫米至75毫米。
在长纤维加强的聚氨酯中,长纤维的含量优选为5-75重量%,更优选为10-60重量%,最优选为20-50重量%。本发明长纤维加强的聚氨酯中长纤维的含量可以在这些值的任意组合的范围内,包括所述的这些值在内。
如本领域技术人员所知道的,聚氨酯是多异氰酸酯与异氰酸酯-活性化合物任选地在发泡剂、催化剂、助剂和添加剂存在下的反应产物。
适合用于本发明的长纤维加强的聚氨酯的异氰酸酯包括未改性的异氰酸酯、改性的多异氰酸酯和异氰酸酯预聚物。这类有机多异氰酸酯包括例如W.Siefken在利比希化学纪事(Justus Liebigs Annalen der Chemie),562,第75-136页中所述类型的脂族、脂环族、芳脂族(araliphatic)、芳族和杂环族多异氰酸酯。这些异氰酸酯的例子包括符合以下通式的化合物:
Q(NCO)n
其中,n是从2-5、优选2-3的数值,Q是含有2-18、优选6-10个碳原子的脂族烃基;含有4-15、优选5-10个碳原子的脂环族烃基;含有8-15、优选8-13个碳原子的芳脂族烃基;或者含有6-15、优选6-13个碳原子的芳族烃基。
合适的异氰酸酯的例子包括1,2-乙二异氰酸酯;1,4-丁二异氰酸酯;1,6-己二异氰酸酯;1,12-十二烷二异氰酸酯;环丁烷-1,3-二异氰酸酯;环己烷-1,3-二异氰酸酯和环己烷-1,4-二异氰酸酯,以及这些异构体的混合物;1-异氰酸基-3,3,5-三甲基-5-异氰酸甲酯基环己烷(异佛尔酮二异氰酸酯,例如,德国专利申请(German Auslegeschrift)1202785和美国专利3401190);2,4-六氢甲苯二异氰酸酯和2,6-六氢甲苯二异氰酸酯以及这些异构体的混合物;二环己基甲烷-4,4’-二异氰酸酯(氢化MDI或HMDI);1,3-苯二异氰酸酯和1,4-苯二异氰酸酯;2,4-甲苯二异氰酸酯和2,6-甲苯二异氰酸酯以及这些异构体的混合物(TDI);二苯基甲烷-2,4’-二异氰酸酯和/或二苯基甲烷-4,4’-二异氰酸酯(MDI);1,5-萘二异氰酸酯;三苯基甲烷-4,4’,4”-三异氰酸酯;可通过苯胺与甲醛缩合,然后再进行光气化反应得到的多苯基-多亚甲基-多异氰酸酯(粗MDI)类,在例如GB 878430和GB 848671中描述了这类异氰酸酯;降冰片烷二异氰酸酯,诸如美国专利3492330中所描述的;美国专利3454606中描述的间-和对-异氰酸苯酯基磺酰基异氰酸酯类;例如美国专利3227138中描述的全氯化芳基多异氰酸酯类;美国专利3152162中描述的含有碳二亚胺基的改性多异氰酸酯类;例如美国专利3394164和3644457中描述的含有氨基甲酸酯基的改性多异氰酸酯类;例如GB 994890、BE761616和NL 7102524中描述的含有脲基甲酸酯基的改性多异氰酸酯类;例如美国专利3002973、德国专利(German Patentschrift)1022789、1222067和1027394以及德国公开说明书(German Offenlegungsschriften)1919034和2004048中描述的含有异氰脲酸酯基的改性多异氰酸酯类;德国专利1230778中描述的含有脲基的改性多异氰酸酯类;例如德国专利1101394、美国专利3124605和3201372以及GB 889050中描述的含有缩二脲基的多异氰酸酯类;例如美国专利3654106中描述的通过调聚反应得到的多异氰酸酯类;例如GB965474和GB 1072956、美国专利3567763和德国专利1231688中描述的含有酯基的多异氰酸酯类;德国专利1072385中描述的上述异氰酸酯与缩醛的反应产物;以及美国专利3455883中描述的含有聚合脂肪酸基团的多异氰酸酯类。也可以使用在异氰酸酯工业规模生产中所累积的含异氰酸酯的蒸馏残余物,所述含异氰酸酯的蒸馏残余物任选以上述一种或多种多异氰酸酯中的溶液形式存在。本领域普通技术人员将会认识到也可以使用上述这些多异氰酸酯的混合物。
异氰酸酯封端的预聚物也可以用于制备本发明复合体的聚氨酯。预聚物可通过使过量的有机多异氰酸酯或它们的混合物与少量的含活性氢的化合物反应来制备,含活性氢的化合物由众所周知的泽瓦夫(Zerewitinoff)测试来确定,如Kohler在“美国化学会志(Journal of the American Chemical Society)”,49,3181(1927)中所描述的。这些化合物及其制备方法是本领域普通技术人员已知的。使用任何一种具体的活性氢化合物不是至关重要的;任何这样的化合物都可以被用于本发明的实施方式中。
尽管任何异氰酸酯-活性化合物均可用于生产聚氨酯,但是聚醚多元醇优选用作异氰酸酯-活性组分。合适的制备聚醚多元醇的方法是已知的,例如在EP-A 283 148,美国专利3,278,457、3,427,256、3,829,505、4,472,560、3,278,458、3,427,334、3,941,849、4,721,818、3,278,459、3,427,335和4,355,188中进行了描述。
可使用的合适的聚醚多元醇是例如那些通过多元醇和环氧烷聚合得到的聚醚多元醇。这类醇的例子包括乙二醇、丙二醇、1,3-丙二醇、1,2-丁二醇、1,3-丁二醇、1,4-丁二醇、1,2-戊二醇、1,4-戊二醇、1,5-戊二醇、1,6-己二醇、1,7-庚二醇、丙三醇、1,1,1-三羟甲基丙烷、1,1,1-三羟甲基乙烷或1,2,6-己三醇。可以使用任何合适的环氧烷,例如环氧乙烷、环氧丙烷、环氧丁烷、氧杂环己烷和这些环氧烷的混合物。聚氧化烯聚醚多元醇可由其它原料制得,这些其它原料是例如四氢呋喃和环氧烷-四氢呋喃混合物,表卤醇如表氯醇,以及氧化芳烯(aralkylene oxides)如氧化苯乙烯。聚氧化烯聚醚多元醇可具有伯羟基或仲羟基。聚醚多元醇包括聚氧乙烯二醇、聚氧丙烯二醇、聚氧丁烯二醇、聚四亚甲基二醇、嵌段共聚物,例如聚氧丙烯和聚氧乙烯二醇的组合、聚-1,2-氧丁烯和聚氧乙烯二醇的组合,以及由两种或多种环氧烷的混合物或相继加入这些环氧烷制得的共聚物二醇。聚氧化烯聚醚多元醇可由任何已知的方法制得。
可包含的发泡剂是已知可通过化学或物理作用产生发泡产品的化合物。水是特别优选的化学发泡剂的例子。物理发泡剂的例子包括具有4-8个碳原子的惰性脂(环)族烃,其在聚氨酯形成条件下蒸发。发泡剂的用量由泡沫材料的目标密度决定。
可以使用那些加快异氰酸酯与异氰酸酯-活性组分的反应的化合物作为用于聚氨酯形成的催化剂。适用于本发明的催化剂包括叔胺和/或有机金属化合物。化合物的例子包括以下:三亚乙基二胺,氨基烷基-和/或氨基苯基-咪唑,例如4-氯-2,5-二甲基-1-(N-甲基氨基乙基)咪唑、2-氨基丙基-4,5-二甲氧基-1-甲基咪唑、1-氨基丙基-2,4,5-三丁基-咪唑、1-氨基乙基-4-己基咪唑、1-氨基丁基-2,5-二甲基咪唑、1-(3-氨基丙基)-2-乙基-4-甲基咪唑、1-(3-氨基丙基)咪唑和/或1-(3-氨基丙基)-2-甲基咪唑,有机羧酸的锡(II)盐,例子是二乙酸锡(II)、二辛酸锡(II)、二乙基己酸锡(II)和二月桂酸锡(II);以及有机羧酸的二烷基锡(IV)盐,例子是二乙酸二丁基锡、二月桂酸二丁基锡、马来酸二丁基锡和二乙酸二辛基锡。
如果需要,聚氨酯形成反应可以在助剂和/或添加剂存在下进行,例如泡孔调节剂、脱模剂、颜料、表面活性化合物和/或稳定剂以抵抗氧化、热或微生物降解或老化。
二异氰酸酯和多元醇混合物可任选地是可紫外固化的,由含单、二或多官能烯健式不饱和基团或多官能环氧基团的可紫外固化的组分组成。可紫外固化的组分可以是液体或固体形式。烯健式不饱和化合物的例子包括苯乙烯衍生物,乙烯醚,乙烯酯,烯丙醚,烯丙酯,N-乙烯基己内酰胺,N-乙烯基己内酯,丙烯酸酯或甲基丙烯酸酯单体。这类化合物的例子还可包括以下所列的低聚物:环氧丙烯酸酯,氨基甲酸酯丙烯酸酯,不饱和聚酯,聚酯丙烯酸酯,聚醚丙烯酸酯,乙烯基丙烯酸酯和多烯/硫醇体系。最常用的可紫外固化的组分包含丙烯酸酯不饱和基团。丙烯酸酯化合物的骨架结构包括脂族、脂环族、芳族、烷氧基化的(alkosylated)、多元醇、聚酯、聚醚、硅酮和聚氨酯。可紫外固化的烯健式不饱和组分可通过光引发剂暴露于辐射源(例如紫外辐射)所引发的自由基聚合方法聚合得到。烯健式不饱和基团在聚合过程中消耗,不饱和基团的转化程度是固化程度的量度。多官能环氧化合物可通过光生活性物质暴露于辐射源(例如紫外辐射)所引发的阳离子聚合方法聚合得到。但是,阳离子紫外固化不限于环氧化物。可辐射固化的组分的重均分子量优选为100-10,000,更优选为400-4,000。不饱和度或环氧基团为2-30重量%。根据具体应用和最终固化的图像性质,可紫外固化的组分与非活性聚合物粘合剂的重量比优选为0.1-100%。
本发明的一个实施方式包括选自辐射固化常用的光引发剂和/或共引发剂。可用于本发明的合适光引发剂是直接裂解(Norrish I型或II型)光引发剂,包括苯偶姻及其衍生物,苯偶酰缩酮及其衍生物,苯乙酮及其衍生物,夺氢光引发剂,包括二苯甲酮及其烷基化的或卤化的衍生物,蒽醌及其衍生物,噻吨酮及其衍生物,和米蚩酮(Michler′s ketone)。合适的光引发剂的例子是二苯甲酮,氯代二苯甲酮,4-苯甲酰基-4′-甲基二苯基硫,丙烯酸酯化的二苯甲酮,4-苯基二苯甲酮,2-氯噻吨酮,异丙基噻吨酮,2,4-二甲基噻吨酮,2,4-二氯噻吨酮,3,3′-二甲基-4-甲氧基二苯甲酮,2,4-二乙基噻吨酮,2,2-二乙氧基苯乙酮,α,α-二氯乙酰,对-苯氧基苯酮,1-羟基环己基苯乙酮,α,α-二甲基,α-羟基苯乙酮,苯偶姻,苯偶姻醚,苄基缩酮,4,4′-二甲基氨基-二苯甲酮,1-苯基-1,2-丙烷二酮-2(O-乙氧基羰基)肟,酰基氧化膦,9,10-菲奎宁等。可有利地使用光敏剂与产生自由基的引发剂的组合,其中所述光敏剂吸收光能,并将其转移到引发剂。光敏剂的例子包括噻吨酮衍生物和叔胺,例如三乙醇胺,甲基二乙醇胺,4-二甲基氨基苯甲酸乙酯,4-二甲基氨基苯甲酸2(正丁氧基)乙酯,对-二甲基-氨基苯甲酸2-乙基己基酯,对-二甲基-氨基苯甲酸戊酯和三异丙醇胺。光引发的阳离子聚合使用络合有机分子的盐来引发含环氧化物的低聚物或单体的阳离子链聚合。阳离子光引发剂包括但不限于具有非亲核性络合金属卤阴离子的二芳基碘鎓和三芳基锍盐。阳离子光引发剂的例子是通式Ar--N2 +X-的芳基重氮盐,其中Ar是芳环,诸如丁苯,硝基苯,二硝基苯等,X是BF4,PF6,AsF6,SbF6,CF3SO3等;通式Ar2I+X-的二芳基碘鎓盐,其中Ar是芳环,诸如甲氧基苯,丁苯,丁氧基苯,辛苯,二癸基苯等,X是低亲核性的离子,诸如BF4,PF6,AsF6,SbF6,CF3SO3等;通式Ar3S+X-的三芳基锍盐,其中Ar是芳环,诸如羟苯,甲氧基苯,丁苯,丁氧基苯,辛苯,十二烷基苯等,X是低亲核性的离子,诸如BF4,PF6,AsF6,SbF6,CF3SO3等。这些组合物可包含0.1-20重量%、优选1-10重量%的光引发剂。通过自由基聚合和阳离子聚合进行的紫外固化技术是众所周知的。紫外固化材料和方法见述于例如R.Mehnert、A.Pincus、I.Janorsky、R.Stowe和A.Berejka的″UV&EB固化技术&设备第I卷(UV&EB Curing Technology&Equipment Volume I)″,其内容通过参考结合于此。
任选地,可将颜料分散在聚合物中,其不溶于水,产生很浓的永久性颜色。这些颜料的例子是有机颜料如酞菁,立索尔颜料(lithols)等,无机颜料如TiO2,炭黑等。酞菁颜料的例子是铜酞菁,一氯铜酞菁和十六氯铜酞菁。适用于本发明的其它有机颜料包括蒽醌还原颜料,诸如还原黄6GLCL1127,醌黄18-1,靛蒽醌CL1106,皮蒽酮CL1096,溴化的皮蒽酮,诸如二溴皮蒽酮,还原亮橙RK,蒽酰胺(anthramide)褐CL1151,二苯并蒽酮绿CL1101,黄烷士林(flavanthrone)黄CL1118;偶氮颜料,诸如甲苯胺红C169和汉撒黄;金属化颜料,诸如偶氮黄和永久红。炭黑可以是任何已知的类型,例如槽法炭黑,炉法炭黑,乙炔黑,热裂法炭黑,灯碳黑和苯胺黑。颜料的用量优选足以使其含量为1-40重量%(以制品的重量为基准计),更优选4-20重量%。
用于生产吹塑硬质空心制品的热塑性材料可独立选择。在本发明的一个实施方式中,吹塑的硬质空心制品的热塑性材料可选自以下所列材料中的至少一种:热塑性聚烯烃(例如,热塑性聚氯乙烯(polyvinylchloride)),热塑性聚氯乙烯(polyvinylchlorine),热塑性聚氨酯,热塑性聚脲,热塑性聚酰胺,热塑性聚酯和热塑性聚碳酸酯。可用于制造吹塑硬质空心制品的热塑性聚烯烃包括例如热塑性聚乙烯,热塑性聚丙烯,乙烯和丙烯的热塑性共聚物,和热塑性聚丁烯。在本发明的一个实施方式中,由可购自LANXESS的热塑性聚酰胺(例如DURETHAN热塑性聚酰胺)制造吹塑硬质空心制品。
文中所用的术语“热固性塑料材料”指通过在化学活性基团(例如活性氢基团)和游离异氰酸酯基之间形成共价键得到的具有三维交联网的塑料材料。可用于制造支承体的热固性塑料材料包括本领域技术人员已知的那些材料,例如交联的聚氨酯,交联的聚环氧化物和交联的聚酯。在热固性塑料材料中,优选的是交联的聚氨酯。可通过本领域已知的反应注塑方法由交联的聚氨酯制造制品。如本领域技术人员已知的,反应注塑方法通常包括将下列组分分别、优选同时注入模具中:(i)活性氢官能组分(例如多元醇和/或多胺);(ii)异氰酸酯官能组分(例如二异氰酸酯如甲苯二异氰酸酯,以及/或者二异氰酸酯如甲苯二异氰酸酯的二聚体和三聚体)。装料的模具可任选地进行加热,以确保和/或促进注入的组分完全反应。在注入的组分完全反应后,打开模具,取出模塑的制品。
如本领域技术人员已知的,在模塑过程中或模塑后,可向空心制品中引入填充材料,诸如聚合物泡沫材料,液体和液体凝胶,以对该元件提供额外的支承。
在本发明的一个实施方式中,叶片或其它大部件可在其一部分表面上具有整体织构结构,通过改变表面、由此改变空气动力学性能,从而提高叶片的效率。可使用多种技术形成整体织构结构,包括织构化的膜,织构化的模具和/或涂层。
利用模内方法在外表面上形成整体织构化的膜。整体膜通常是塑料膜,例如热塑性或热固性塑料膜,可以是透明的,着色的或不透明的和织构化的。另外,整体膜可在其上具有标记,图案和/或印刷物。较佳地,整体膜是热塑性膜,例如热塑性聚氨酯或聚碳酸酯膜。优选在模塑过程中将整体膜结合到外表面中,即利用模内方法。例如,优选使热塑性聚氨酯膜插入物与膜内表面的至少一部分接触。在模塑过程中,构成制品的熔融模塑材料与膜插入物接触,并与其熔合。在将制品从模具中取出后,部件具有与其至少一部分外表面粘合的整体织构化的膜。
或者,制品的外表面可具有模内织构。模内织构有助于通过改变叶片的空气动力学性能来提高叶片效率。优选通过叶片在其中形成的模具的内表面上和/或内表面中的多个凸起部分和/或凹陷来形成模内织构。任选地,可在模具表面上添加涂层,以提高模内织构,以及/或者有助于制品从模具中取出。
已经提出了各种方法,通过在基材上沉积材料层来形成三维物体。这种层化制造方法也称为固体自由成形制造(solid free-form fabrication(SFF))或快速原型操作(RP)。可依据该方法处理各种材料和材料组合,包括塑料、蜡、金属、陶瓷、水泥等材料。一般而言,RP技术利用表示待形成的物体的连续截面的数据由构建介质逐层建立三维物体。计算机辅助设计和计算机辅助制造系统(通常称为CAD/CAM系统)常常对RP系统提供对象表示。快速原型和制造(RP&M)的三个主要模块包括固体图像的立体光刻、激光烧结和喷墨印刷。
激光烧结是由可热熔粉末的薄层形成固体图像,所述可热熔粉末包括陶瓷、聚合物和聚合物涂布的金属,向该可热熔粉末提供足够的能量,以使层固化。喷墨印刷是由与粘合剂混合时固化的粉末形成固体图像。本发明主要涉及的立体光刻法是由可聚合液体(常称为树脂)的薄层形成固体图像。
Khoshevis在美国专利5,529,471、5,656,230、6,589,471、7,153,454和7,452,196以及美国公开专利申请2005/0196482、2007/0138678、2007/0138687和2007/0181519中描述了添加自动化制造技术,这些专利文献的内容通过参考结合于此。
尽管本文中就生产风轮机叶片描述了本发明,但是本发明人认为该方法可用于生产各种其它大物体,包括风轮机塔,汽车结构板,农用收割机(例如联合收割机)所用的板,客机的复合结构,建筑物和建筑结构(例如小室)中所用的板,以及大废石仓。
实施例
通过以下实施例进一步说明本发明,但本发明不限于以下实施例。
图1显示了使用自动化系统来产生混凝土模具,该模具用于制造极大的部件,如风轮机叶片。这种大型模具提供所需的稳定性和刚性结构,这些性质对成功复制这些巨型部件至关重要。另外,这些模具可在风轮机制造场所或其附近方便地生产,并且较便宜。
参考图1可以知道,形成模具的方法包括使用配有挤出机模头12的材料进料管10,从而以受控的方式递送混凝土,逐层制造模具。挤出机管和模头的组合是计算机引导的。为了开发所需的计算机模式,使用CAD(计算机辅助设计)软件设计模具。然后,传递设计数据,用于编程CAM(计算机辅助制造)计算机。如图所示,CAM计算机(未示出)指令材料进料管10和挤出机模头12的组合,逐层形成模具。随着层16、18、20和22被设置,用与进料管10一体化并受计算机控制的抹刀将挤出的混凝土的顶部和侧部抹平。在模具构造过程中插入加热元件,最终的模具装配有密封联结的盖子,该盖子也被加热。
图2显示使用图1所示的自动化系统的在建中的风轮机塔基座。如果需要,可在构建过程中插入加强棒,以提供额外的结构强度。
参看图3,由混合头32(例如,来自卡斯马弗(Krauss-Maffei))向敞口模具30中进料。在混合头32,从玻璃粗纱34将玻璃纤维原丝切割到合适的长度,同时,将用泵从容纳异氰酸酯36和多元醇38的储罐抽出的各聚氨酯组分合并。混合头32在连续从敞口模具30上通过时,同时分配聚氨酯反应混合物和切断的玻璃粗纱。通过与计算机控制的台架42连接的自动装置40控制聚氨酯反应混合物和玻璃纤维在模具30上的分布。如图所示,台架42安装在轨道上,使得自动装置40能自由地移动,因而完全覆盖模具空腔44。对空腔44填料,然后盖上模具盖46。模具30保持闭合约1.5-6分钟,以使玻璃纤维强化层在约120-190℉的温度下固化。使用脱模剂来确保复合物制品可接受的脱模。将混合头32中的物质分配到模具30中所需的时间约为60秒。
给出本发明的上述实施例是出于说明而非限制的目的。对本领域普通技术人员显而易见的是,在不偏离本发明的精神和范围的情况下,可以各种方式修改或调整本文所述的实施方式。本发明的范围由所附权利要求书限定。
Claims (12)
1.一种制造聚氨酯风轮机叶片的方法,该方法包括:
在风电场处或风电场附近形成用于风轮机叶片的模具;
用自动化反应注塑(“RIM”)机将异氰酸酯和异氰酸酯活性组分注入所述模具;
闭合所述模具并对该模具进行加压和加热,以使所得的聚氨酯固化;和
将叶片安装在风轮机中。
2.如权利要求1所述的方法,其特征在于,使用辐射使得所述聚氨酯固化。
3.如权利要求1所述的方法,其特征在于,通过大规模快速原型操作实现所述形成模具的操作。
4.如权利要求1所述的方法,其特征在于,通过添加自动化制造实现所述形成模具的操作。
5.如权利要求1所述的方法,其特征在于,所述形成模具的操作包括用大规模快速原型操作制造风轮机叶片的正像,形成负像,铸造或模塑高强度复合件。
6.如权利要求4所述的方法,其特征在于,所述高强度复合件包含金属、水泥和聚合物中的至少一种。
7.一种制造聚氨酯风轮机叶片的方法,该方法包括:
在风电场处或风电场附近形成风轮机叶片模具;
用自动化长纤维注塑(“LFI”)机注入异氰酸酯、异氰酸酯活性组分和长纤维;
闭合所述模具并对该模具进行加压和加热,以使所得的聚氨酯固化;和
将叶片安装在风轮机中。
8.如权利要求7所述的方法,其特征在于,使用辐射使得所述聚氨酯固化。
9.如权利要求7所述的方法,其特征在于,通过大规模快速原型操作实现所述形成模具的操作。
10.如权利要求7所述的方法,其特征在于,通过添加自动化制造实现所述形成模具的操作。
11.如权利要求7所述的方法,其特征在于,所述形成模具的操作包括用大规模快速原型操作制造风轮机叶片的正像,形成负像,铸造或模塑高强度复合件。
12.如权利要求11所述的方法,其特征在于,所述高强度复合件包含选自金属、水泥和聚合物中的一种或多种。
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WO2011028271A2 (en) | 2011-03-10 |
JP6073418B2 (ja) | 2017-02-01 |
EP2473333A4 (en) | 2017-09-13 |
KR20120083302A (ko) | 2012-07-25 |
BR112012008312A2 (pt) | 2019-09-24 |
ZA201201243B (en) | 2013-04-24 |
MX2012002615A (es) | 2012-04-20 |
WO2011028271A3 (en) | 2011-07-28 |
RU2547507C2 (ru) | 2015-04-10 |
JP2013504007A (ja) | 2013-02-04 |
JP2015214981A (ja) | 2015-12-03 |
RU2012112871A (ru) | 2013-10-10 |
US20120159785A1 (en) | 2012-06-28 |
AU2010290032A1 (en) | 2012-02-23 |
CA2772495A1 (en) | 2011-03-10 |
IN2012DN01887A (zh) | 2015-07-24 |
EP2473333A2 (en) | 2012-07-11 |
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