CN110067693B - 柔性轻木木质板,转子叶片,风力涡轮机和方法 - Google Patents
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Abstract
柔性轻木木质板,转子叶片,风力涡轮机和方法。一种用于风力涡轮机(1)的转子叶片(5)的柔性轻木木质板(9),包括多个轻木木质模块(10)和聚合物膜(19),聚合物膜(19)附着至每个轻木木质模块(10)的表面(20),以将轻木木质模块(10)连接在一起。柔性轻木木质板(9)具有以下优点。聚合物膜(19)的粘合面积明显大于玻璃纤维网的粘合面积。这转而降低了在处理柔性轻木木质板(9)期间轻木木质模块(10)脱落的风险。可以选择具有相对于最大叶片固化温度的高熔融温度的聚合物膜(19),以避免固化过程引起的分层。此外,由于附着至表面(20)的聚合物膜(19),与目前使用的玻璃纤维网相比可以实现更均匀的粘合。
Description
技术领域
本发明涉及一种用于风力涡轮机的转子叶片的柔性轻木木质板,涉及一种具有这种柔性轻木木质板的转子叶片,涉及一种具有这种柔性轻木木质板和/或这种转子叶片的风力涡轮机,并且涉及一种用于制造用于这种转子叶片的柔性轻木木质板的方法。
背景技术
现代风力涡轮机转子叶片由纤维增强塑料制成。转子叶片通常包括具有倒圆的前缘和尖锐的后缘的翼型件。转子叶片以其叶片根部连接至风力涡轮机的轮毂。这种转子叶片可包括木材,尤其是轻木木材。来自轻木(Ochroma pyramidale)(通常称为轻木树)的木材是非常软且轻的,具有粗糙的粗疏纹理。干轻木木材的密度在40-340kg/m3的范围内,具有的典型的密度约160kg/m3。由于轻木木材具有这些出色的性能,它经常用在飞机和风力涡轮机技术中以制造轻质部件。
通过在轻木木质板上设置玻璃纤维网或网格,特别是以所谓的玻璃纤维稀松平纹织物的形式,实现使轻木木质板具有柔性以使其能够符合弯曲的风力涡轮机叶片几何形状。可以通过将湿胶添加至玻璃纤维网,并且随后将其滚到轻木木质板上,然后使胶固化来施加玻璃纤维网或者可以通过应用升高的温度,通过用热塑性预涂胶将玻璃纤维网滚到轻木木质板上来施加玻璃纤维网。在施加玻璃纤维网并使胶固化之后,轻木木质板被切割成模块,这些模块仅通过玻璃纤维网彼此连接。现在,轻木木质板是柔性的,并且能够适应曲面。
发明内容
本发明的一个目的是提供一种用于风力涡轮机的转子叶片的改善的柔性轻木木质板。
因此,提供了一种用于风力涡轮机的转子叶片的柔性轻木木质板。柔性轻木木质板包括多个轻木木质模块和聚合物膜,聚合物膜附着至每个轻木木质模块的表面以将轻木木质模块连接在一起。
通过应用聚合物膜代替玻璃纤维网,能够实现以下优点。聚合物膜的粘合面积明显大于玻璃纤维网的粘合面积。这转而降低了在处理柔性轻木木质板期间轻木木质模块脱落的风险。可以选择具有相对于最大叶片固化温度的高熔融温度的聚合物膜,以避免固化过程引起的分层。此外,由于附着至表面的聚合物膜,与目前使用的玻璃纤维网相比可以实现更均匀的粘合。
优选地,聚合物膜直接附着至表面。“直接”指的是不需要额外的树脂来将聚合物膜固定至表面。聚合物膜本身可以作为粘合剂或胶。优选地,轻木木质模块仅通过聚合物膜彼此连接。特别地,轻木木质模块具有第一表面和第二表面,其中聚合物膜附着至第一表面,第二表面背离聚合物膜。聚合物膜可被称为聚合物箔。聚合物膜可具有几微米(μm)至几毫米(mm)的厚度。聚合物膜可以是穿孔的或未穿孔的,特别是光滑的。聚合物膜防止轻木木质模块分散开,并且从而保持柔性轻木木质板的完整性。
根据实施例,聚合物膜是未增强的。优选地,聚合物膜不具有以玻璃纤维,碳纤维等形式的增强物。特别地,聚合物膜不含纤维或是无纤维的。
根据另外的实施例,聚合物膜是单层或多层的。“单层”指的是聚合物膜仅具有一层。“多层”指的是聚合物膜包括结合在一起的多个薄聚合物片。特别地,这些片可以全部由相同材料制成或由不同材料制成。因此,聚合物膜的机械性能可以广泛变化。
根据另外的实施例,轻木木质模块的木质纤维布置成垂直于轻木木质模块的表面。优选地,每个轻木木质模块具有第一表面和第二表面,其中聚合物膜附着至第一表面,第二表面背离聚合物膜。特别地,木质纤维布置成垂直于两个表面。
根据另外的实施例,聚合物膜包括粘合面和非粘合面,其中粘合面附着至每个轻木木质模块的表面,非粘合面背离每个轻木木质模块的表面。粘合面可以被提供有压敏粘合剂(PSA,自粘合剂,自粘粘合剂)。PSA是在施压以使粘合剂与被粘物粘合时形成结合的粘合剂。激活PSA不需要溶剂,水或热。
根据另外的实施例,制成聚合物膜的材料本身具有粘合性。为了将聚合物膜结合至轻木木质模块,聚合物膜可以至少部分熔融。优选地,选择具有相对于最大叶片固化温度的高熔融温度的聚合物膜,以避免固化过程引起的分层。
根据另外的实施例,轻木木质模块布置成棋盘状样式。棋盘状样式可以被称为矩阵状样式。优选地,每个轻木木质模块由四个另外的轻木木质模块邻接。
根据另外的实施例,轻木木质模块是矩形或方形的。特别地,轻木木质模块是立方体形状的。
根据另外的实施例,在轻木木质模块之间布置第一切口和第二切口,其中第一切口布置成垂直于第二切口。交叉切口将柔性轻木木质板细分成轻木木质模块。可以通过刀片或锯制造切口。
优选地,第一切口允许柔性轻木木质板围绕其宽度方向弯曲,而第二切口允许围绕其长度方向弯曲。宽度方向布置成垂直于长度方向。
此外,提供了一种用于风力涡轮机的转子叶片,其包括至少一个这种柔性轻木木质板。然而,柔性轻木木质板可以用在涉及风力涡轮机的任何其它应用中。
另外,提供了一种风力涡轮机,其包括至少一个这种柔性轻木木质板和/或至少一个这种转子叶片。优选地,风力涡轮机具有多个转子叶片。“风力涡轮机”目前指的是将风的动能转换成旋转能的装置,旋转能可以再次通过该装置转换成电能。
此外,提供了一种用于制造用于风力涡轮机的转子叶片的柔性轻木木质板的方法。该方法包括以下步骤:a)提供刚性轻木木质板,b)将聚合物膜附着至刚性轻木木质板的表面,以及c)将刚性轻木木质板切割成多个轻木木质模块以获得柔性轻木木质板。
优选地,通过刀片或锯进行切割。切口彼此垂直延伸,以产生轻木木质模块的棋盘状或矩阵状样式。特别地,刚性轻木木质板是刚性轻木木质端纹板,其中木质纤维垂直于刚性轻木木质板的上述表面延伸。
根据实施例,在步骤b)中,通过施加压力和/或施加热将聚合物膜附着至刚性轻木木质板的表面。可以施加压力和热两者。替代地,可以仅施加压力或仅施加热。在仅使用压力的情况下,聚合物膜可以设置有PSA。在仅使用热或使用压力和热的情况下,聚合物膜可以设置有热熔粘合剂或者可以由热熔粘合剂制成。优选地,选择具有相对于最大叶片固化温度的高熔融温度的聚合物膜,以避免固化过程引起的分层。
根据另外的实施例,通过滚子施加压力和/或热。可以加热滚子。滚子可以是用于制造柔性轻木木质板的设备的一部分。该设备还可包括支撑件,在施加聚合物膜之前,刚性轻木木质板放置在支撑件上。
根据另外的实施例,在步骤b)中,通过将聚合物膜直接挤出到表面上而将聚合物膜附着至刚性轻木木质板的表面。挤出机可用于将聚合物膜施加到表面上。制造聚合物膜的材料(优选热塑性塑料或热熔粘合剂)在其施加到表面上之前熔融。优选地,熔融材料直接施加至表面以直接在表面上形成聚合物膜。聚合物膜与表面之间的粘合可以通过该方法显着改善。热塑性塑料或热软性塑料是塑料材料(尤其是聚合物),其在特定温度(特别是熔融温度)之上变成柔韧的或可模塑的,并且经冷却固化。优选地,聚合物膜的熔融温度等于或高于最大叶片固化温度。
本发明的其它可能的实施方式或替代解决方案还包括上文或下文关于实施例所描述的特征的组合(这里未明确提及)。本领域技术人员也可以将个别或单独的方面和特征添加到本发明的最基本形式。
附图说明
本发明的其它实施例,特征和优点将从随后的说明和从属权利要求,结合附图而变得明显,其中:
图1是根据一个实施例的风力涡轮机的透视图;
图2是根据一个实施例的风力涡轮机转子叶片的透视图;
图3示出了根据一个实施例的柔性木质板的透视图;
图4示出了根据图3的柔性木质板的详细视图;
图5示出了用于制造根据图3的柔性木质板的设备的实施例的侧视图;和
图6示出了用于制造根据图3的柔性木质板的方法的实施例的框图。
在附图中,除非另有说明,否则相同的附图标记表示相同或功能等效的元件。
具体实施方式
图1示出了根据一个实施例的风力涡轮机1。
风力涡轮机1包括转子2,转子2连接至布置在机舱3内部的发电机(未示出)。机舱3布置在风力涡轮机1的塔4的上端部。
转子2包括三个转子叶片5。转子叶片5连接至风力涡轮机1的轮毂6。这种转子2可具有范围从例如30至160米或甚至更大的直径。转子叶片5承受高风载荷。同时,转子叶片5需要是轻质的。由于这些原因,现代风力涡轮机1中的转子叶片5由纤维增强复合材料制成。其中,出于成本原因,玻璃纤维通常优于碳纤维。通常,使用单向纤维垫形式的玻璃纤维。
图2示出了根据一个实施例的转子叶片5。
转子叶片5包括空气动力学设计的部分7和叶片根部8,其中空气动力学设计的部分7成形用于最佳地开发风能,叶片根部8用于将转子叶片5连接至轮毂6。
图3示出了可用于制造转子叶片5的柔性木质板9。
柔性木质板9可以是用于制造转子叶片5的夹层板的一部分。柔性木质板9是柔性的,以便使其能够遵循转子叶片5的弯曲几何形状。优选地,柔性木质板9是由非常轻质的轻木木材制成。通过将端纹轻木板切割成矩形模块10来制造柔性木质板9,矩形模块10中仅一个在图3中提供有附图标记。模块10可以被称为轻木模块或轻木木质模块。柔性木质板9可以被称为柔性轻木板或柔性轻木木质板。柔性木质板9可具有数百至数千或甚至更多的模块10。
为提供模块10,在柔性木质板9中设置第一切口11至14。第一切口11至14的数量是任意的。第一切口11至14沿柔性木质板9的宽度方向W延伸。第一切口11至14布置成彼此平行。在仅设置第一切口11至14的情况下,模块10具有细长的矩形形状。
可选地,设置有第二切口15至18,其垂直于第一切口11至14延伸。第二切口15至18沿柔性木质板9的长度方向L延伸。第二切口15至18布置成彼此平行。第一切口11至14和第二切口15至18将柔性木质板9细分为任意数量的方形模块10。模块10布置成矩阵状或棋盘状样式。
第一切口11至14允许柔性木质板9围绕宽度方向W弯曲,而第二切口15至18允许围绕长度方向L弯曲。切口11至18是通过切割或锯切端纹轻木板而提供的。在切割或锯切之后,柔性木质板9可以被称为网格刻划板,特别是网格刻划轻木木质板。为了在切割或锯切之后保持柔性木质板9的完整性,在切割之前提供图3中未示出的柔性载体层(未示出)。在转子叶片5的制造的处理期间,柔性载体层保持柔性木质板9的完整性。柔性载体层设置在图3中所示的柔性木质板9的上表面上。
通常,柔性载体层以玻璃纤维网或网格的形式被提供,特别是以所谓的玻璃纤维稀松平纹织物的形式。通常,用于保持柔性木质板9的完整性的技术是在将柔性木质板9切割成模块10之前将玻璃纤维网粘合在柔性木质板9的一面上。可以通过将湿胶添加至玻璃纤维网,并且随后将其滚到柔性木质板9的一个表面上,然后使胶固化来施加玻璃纤维网或者可以通过应用升高的温度,通过用热塑性预涂胶将玻璃纤维网滚到柔性木质板9的一个表面上来施加玻璃纤维网。随后,将柔性木质板9切割成模块10。
然而,在某些情形中和/或在某些情况下,使用玻璃纤维网可能导致玻璃纤维网与柔性木质板9的木质表面之间的粘合不足。此外,已经观察到在固化转子叶片5期间相对高的加工温度会超过用于固定玻璃纤维网的胶的允许温度的迹象,并且因此会是关于风力涡轮机玻璃纤维增强塑料叶片夹层结构中的固化过程引起的分层的至少一个影响因素。
图4示出了柔性木质板9的详细视图。
为了改善柔性木质板9的完整性和可操作性,柔性木质板9设置有聚合物膜19形式的载体层。如在图4中可见,柔性木质板9的每个模块10具有面向聚合物膜19的第一表面20和避开聚合物膜19的第二表面21。第一表面20和第二表面21彼此平行地延伸并且布置成距彼此一定距离。聚合物膜19附着至第一表面20。模块10的木质纤维22垂直于表面20、21延伸。
聚合物膜19可以是穿孔的。这意味着,聚合物膜19可以具有以均匀样式布置的多个破口。聚合物膜19也可以是光滑的,这意味着未穿孔。优选地,聚合物膜19具有粘合性。特别地,聚合物膜19包括粘合面23和非粘合面24,其中粘合面23附着至模块10的第一表面20,非粘合面24背离第一表面20。粘合面23可包括胶。替代地,聚合物膜19的材料可具有固有的粘合性。这意味着,聚合物膜19的材料本身用作粘合剂。因此,不需要将额外的粘合剂施加到粘合面23。
在将柔性木质板9切割成模块10之前,可以将粘合面23施加至木质第一表面20。可替代的制造途径是在将柔性木质板9切割成模块之前将聚合物膜19直接挤出至第一表面20。聚合物膜19可以是单层聚合物膜。换言之,聚合物膜19仅具有一层。替代地,聚合物膜19可以是多层聚合物膜。这意味着,聚合物膜19包括多个结合在一起的薄聚合物片。这些片可以全部由相同材料制成或由不同材料制成。因此,聚合物膜19的机械性能可以广泛变化。
图5示出了用于制造柔性木质板9的设备25。
设备25包括支撑件26,在支撑件26上放置有刚性木质端纹板27,尤其是刚性轻木端纹板。到目前为止,刚性木质端纹板27未被切割成模块10。其第二表面21放置在支撑件26上,并且其第一表面20背向支撑件25。如前所述,木质纤维22垂直于表面20、21延伸。刚性木质端纹板27可以被称为刚性轻木木质板。
设备25还包括滚子28。滚子28可以围绕旋转轴线M沿旋转方向R旋转。旋转方向R可以顺时针定向。滚子28也可以沿x方向x线性移动。为了在聚合物膜19上产生压力,可以使滚子28在y方向y上压靠聚合物膜19。
为了将聚合物膜19附着至刚性木质端纹板27的第一表面20上,聚合物膜19被施加至第一表面20。随后或同时,压力p和/或热量H可以被施加至聚合物膜19,以将其结合至第一表面20。滚子28可以包括用于将热量H施加至聚合物膜19的加热设备。在将聚合物膜19结合至第一表面20之后,刚性木质端纹板27被切割(网格刻划)成模块10以获得柔性木质板9。
图6示出了用于制造柔性木质板19的方法的实施例的框图。
在步骤S1中,提供刚性木质端纹板27。在随后的步骤S2中,聚合物膜19附着至刚性木质端纹板27的第一表面20。在随后的步骤S3中,将刚性木质端纹板27切割成多个模块10以获得柔性木质板。可以通过刀片或锯进行切割。
通过应用聚合物膜19代替玻璃纤维网,能够实现以下优点。聚合物膜19的粘合面积明显大于玻璃纤维网的粘合面积。这转而降低了在处理柔性木质板9期间模块10脱落的风险。可以选择具有相对于最大叶片固化温度的高熔融温度的聚合物膜19,以避免固化过程引起的分层。此外,由于附着至第一表面20的聚合物膜19,与目前使用的玻璃纤维网相比可以实现更均匀的粘合。
尽管已经根据优选的实施例描述了本发明,但是对于本领域技术人员显而易见的是,在所有实施例中都可以进行修改。
Claims (14)
1.一种用于风力涡轮机(1)的转子叶片(5)的柔性轻木木质板(9),包括多个轻木木质模块(10)和聚合物膜(19),所述聚合物膜(19)附着至每个轻木木质模块(10)的表面(20),以将所述轻木木质模块(10)连接在一起,其中,所述聚合物膜(19)是未增强的,并且其中,所述聚合物膜(19)的熔融温度等于或高于最大叶片固化温度。
2.根据权利要求1所述的柔性轻木木质板,其中所述聚合物膜(19)是单层的或多层的。
3.根据权利要求1或2所述的柔性轻木木质板,其中,所述轻木木质模块(10)的木质纤维(22)布置成垂直于所述轻木木质模块(10)的表面(20)。
4.根据权利要求1或2所述的柔性轻木木质板,其中,所述聚合物膜(19)包括粘合面(23)和非粘合面(24),所述粘合面(23)附着至每个轻木木质模块(10)的表面(20),所述非粘合面(24)背离每个轻木木质模块(10)的表面(20)。
5.根据权利要求1或2所述的柔性轻木木质板,其中,制成所述聚合物膜(19)的材料本身具有粘合性。
6.根据权利要求1或2所述的柔性轻木木质板,其中,所述轻木木质模块(10)布置成棋盘状样式。
7.根据权利要求1或2所述的柔性轻木木质板,其中,所述轻木木质模块(10)是长方形的或正方形的。
8.根据权利要求1或2所述的柔性轻木木质板,其中,在所述轻木木质模块(10)之间布置第一切口(11-14)和第二切口(15-18),并且其中,所述第一切口(11-14)布置成垂直于所述第二切口(15-18)。
9.一种用于风力涡轮机(1)的转子叶片(5),包括至少一个根据权利要求1至8中任一项所述的柔性轻木木质板(9)。
10.一种风力涡轮机(1),包括至少一个根据权利要求1至8中任一项所述的柔性轻木木质板(9)或至少一个根据权利要求9所述的转子叶片(5)。
11.一种用于制造用于风力涡轮机(1)的转子叶片(5)的柔性轻木木质板(9)的方法,包括以下步骤:
a)提供(S1)刚性轻木木质板(27),
b)将聚合物膜(19)附着(S2)至所述刚性轻木木质板(27)的表面(20)上,其中,所述聚合物膜(19)是未增强的,并且其中,所述聚合物膜(19)的熔融温度等于或高于最大叶片固化温度,并且
c)将所述刚性轻木木质板(27)切割(S3)成多个轻木木质模块(10),以获得柔性轻木木质板(9)。
12.根据权利要求11所述的方法,其中,在步骤b)中,通过施加压力(p)和/或施加热量(H)将所述聚合物膜(19)附着至所述刚性轻木木质板(27)的表面(20)。
13.根据权利要求12所述的方法,其中,通过滚子(28)施加压力(p)和/或热量(H)。
14.根据权利要求11所述的方法,其中,在步骤b)中,通过将所述聚合物膜(19)直接挤出到表面(20)上而将所述聚合物膜(19)附着至所述刚性轻木木质板(27)的表面(20)上。
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2018
- 2018-01-24 EP EP18153208.6A patent/EP3517772B1/en active Active
- 2018-01-24 DK DK18153208.6T patent/DK3517772T3/da active
- 2018-01-24 PT PT181532086T patent/PT3517772T/pt unknown
- 2018-01-24 ES ES18153208T patent/ES2883681T3/es active Active
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2019
- 2019-01-16 US US16/249,106 patent/US11401912B2/en active Active
- 2019-01-24 CN CN201910068176.3A patent/CN110067693B/zh active Active
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CN103842644A (zh) * | 2011-07-25 | 2014-06-04 | 林木筏编造有限公司 | 用于生产柔性端纹巴沙木面板的方法 |
Also Published As
Publication number | Publication date |
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EP3517772A1 (en) | 2019-07-31 |
US20190226447A1 (en) | 2019-07-25 |
PT3517772T (pt) | 2021-06-30 |
CN110067693A (zh) | 2019-07-30 |
ES2883681T3 (es) | 2021-12-09 |
US11401912B2 (en) | 2022-08-02 |
EP3517772B1 (en) | 2021-06-09 |
DK3517772T3 (da) | 2021-07-05 |
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