CN110748452A - 复合材料、风力涡轮机叶片、风力涡轮机和用于产生复合材料的方法 - Google Patents

复合材料、风力涡轮机叶片、风力涡轮机和用于产生复合材料的方法 Download PDF

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CN110748452A
CN110748452A CN201910666137.3A CN201910666137A CN110748452A CN 110748452 A CN110748452 A CN 110748452A CN 201910666137 A CN201910666137 A CN 201910666137A CN 110748452 A CN110748452 A CN 110748452A
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composite material
rigid
elements
wind turbine
flexible
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T.B.温伦德
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Siemens Gamesa Renewable Energy AS
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03DWIND MOTORS
    • F03D1/00Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06Rotors
    • F03D1/065Rotors characterised by their construction elements
    • F03D1/0675Rotors characterised by their construction elements of the blades
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29DPRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00Subject matter not provided for in other groups of this subclass
    • B29D99/0025Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • B29D99/0028Producing blades or the like, e.g. blades for turbines, propellers, or wings hollow blades
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03DWIND MOTORS
    • F03D1/00Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06Rotors
    • F03D1/0608Rotors characterised by their aerodynamic shape
    • F03D1/0633Rotors characterised by their aerodynamic shape of the blades
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03DWIND MOTORS
    • F03D80/00Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/20Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror"
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
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    • B29C66/11Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114Single butt joints
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    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
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    • B29C66/43Joining a relatively small portion of the surface of said articles
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7315Mechanical properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract

本发明涉及复合材料、风力涡轮机叶片、风力涡轮机和用于产生复合材料的方法。一种用于风力涡轮机叶片(5)的复合材料(9),所述复合材料(9)包括多个刚性元件(11)和多个柔性元件(12),其中,每个柔性元件(12)被布置在两个刚性元件(11)之间并且连接到所述两个刚性元件(11),使得所述刚性元件(11)借助于所述柔性元件(12)柔性地连接到彼此。通过使用刚性元件(11)之间的空隙能够实现复合材料(9)的柔性。因此,当复合材料(9)被放置在弯曲表面(17)上时,可减少或避免刚性元件(11)之间的空腔。

Description

复合材料、风力涡轮机叶片、风力涡轮机和用于产生复合材料 的方法
技术领域
本发明涉及复合材料、包括这样的复合材料的风力涡轮机叶片、包括这样的风力涡轮机叶片的风力涡轮机以及用于产生该复合材料的方法。
背景技术
现代风力涡轮机的转子叶片由纤维增强塑料构建。转子叶片通常包括具有圆形的前缘和尖锐的后缘的翼型。转子叶片利用其叶片根部连接到风力涡轮机的轮毂。目前,需要长的风力涡轮机叶片,其需要更强的夹芯材料。
这种类型的转子叶片可包括木材,特别是轻木(balsa wood)。来自通常称为巴沙树(balsa tree)的Ochroma pyramidale的木材非常软且轻,具有粗疏纹理(coarse, opengrain)。干轻木的密度范围从40-340kg/m3,其中典型的密度为大约160kg/m3。由于轻木具有这些突出的特性,它通常在飞机和风力涡轮机技术中被用于生产轻质部件。
通过在轻木板上特别是以所谓的稀松布(scrim cloth)的形式设置玻璃纤维网或网状物,实现了使轻木板具有柔性,以使其能够遵循弯曲的风力涡轮机叶片的几何形状。玻璃纤维网可通过如下方式来施加,即:将湿胶添加到玻璃纤维网,并且随后,将其滚动到轻木板上,继之以使胶固化,或者通过施加高温来使带有热塑性预涂胶的玻璃纤维网滚动到轻木板上。在施加玻璃纤维网并使胶固化之后,轻木板被切割成仅借助于玻璃纤维网连接到彼此的模块。该轻木板现在是柔性的,并且可适应弯曲的表面。
发明内容
本发明的一个目的在于提供一种用于风力涡轮机叶片的改进的复合材料。
因此,提供了一种用于风力涡轮机叶片的复合材料。该复合材料包括多个刚性元件和多个柔性元件,其中,每个柔性元件被布置在两个刚性元件之间并且被连接到这两个刚性元件,使得该刚性元件借助于该柔性元件柔性地连接到彼此。
这具有如下优点,即:通过使用刚性元件之间的空隙可实现复合材料的柔性。因此,当复合材料被放置在弯曲表面上并且因此弯曲时,可减少或避免刚性元件之间的空腔。当使用厚的刚性元件时,这是特别重要的。在刚性元件之间使用柔性材料具有可避免复合材料破裂的优点。因此,当生产、特别是切割刚性元件时,可以提高效率。此外,还可提高叶片制造过程的效率。
所述刚性元件和柔性元件由不同的材料制成。优选地,所述复合材料是双材料的夹芯材料。特别地,所述复合材料是板。“刚性元件”和“柔性元件”意味着该刚性元件具有比该柔性元件更大的刚度。优选地,每个柔性元件被连接到一个刚性元件的侧面,并且连接到另一刚性元件的另一侧面,其中,当所述复合材料均匀地展开、即不弯曲时,该侧面和该另一侧面面向彼此。特别地,所有刚性元件都是相同的。例如,所有柔性元件都设置成相同。
根据一个实施例,所述复合材料形成平坦的和/或适应性强(adaptable)的材料,所述材料构造成在安装时适应弯曲表面。
因此,所述复合材料可适应于该弯曲表面而不会破裂。优选地,设置具有弯曲表面和安装在弯曲表面上的复合材料的叶片壳体。
根据另一实施例,所述柔性元件完全填充所述刚性元件之间的间隙,使得由所述刚性元件和所述柔性元件形成的表面是平坦的。
特别地,所述柔性元件被设置为所述刚性元件之间的填充材料。这具有如下优点,即:在安装所述复合材料之后,可避免所述复合材料中的不期望的空腔。因此,在这样的空腔中可避免附加的填充材料,特别是叶片树脂。由于所述柔性材料例如比叶片树脂更刚性,因此可提高叶片壳体的刚性。
根据另一实施例,所述刚性元件和所述柔性元件是条形的。
这意味着刚性元件的长度是刚性元件的高度和/或宽度的若干倍,特别是至少10倍。优选地,所述刚性元件被设置为条或梁。
根据另一实施例,所述刚性元件由轻木或刚性多孔泡沫制成。
这具有如下优点,即:轻木具有优异的重量和机械特性。此外,轻木还是可再生资源。优选地,所述复合材料是柔性木板。例如,所述刚性多孔泡沫可包括金属,特别是铝,或塑料材料,或者由上述材料制成。
根据另一实施例,每个刚性元件具有矩形剖面形状,所述矩形剖面形状特别是沿所述刚性元件的纵向轴线是不变的。
这具有如下优点,即:特别是借助于切割和/或锯切,可以简单地产生所述刚性元件。优选地,当所述复合材料均匀地展开时,所述柔性元件也可具有矩形剖面形状。
根据另一实施例,所述柔性元件是可塑性或弹性变形的。
“可弹性变形”意味着柔性元件在初始状态下变形恢复。“可塑性变形”意味着柔性元件由于其可延展性而能够不可逆地变形。优选地,所述柔性元件具有比所述刚性元件更大的可延展性。所述柔性元件的可延展性被选择成使得例如仅通过重力或通过将复合材料手动强制成叶片几何形状来对复合材料产生可塑性,使得复合材料由于塑性变形而保持这种形状。
根据另一实施例,所述柔性元件借助于粘合剂或热板焊接来连接到所述刚性元件。
因此,可实现复合材料的足够强度。此外,还可避免刚性元件从复合材料分离。
根据另一实施例,所述刚性元件具有第一弹性模量,并且所述柔性元件具有第二弹性模量,其中,所述第一弹性模量大于所述第二弹性模量。
优选地,所述第一弹性模量为所述第二弹性模量的至少1.5倍、2倍、3倍或4倍。因此,所述刚性元件比所述柔性元件明显更刚硬。
根据另一实施例,介于3个和20个之间、4个和15个之间或4个和10个之间、特别是4个、5个、6个或7个的刚性元件被连接以形成单个模块,所述模块能够作为单件处理。
因此,可以提供可通过组装工人的手力来管理的模块。优选地,所述模块借助于切割穿过两个柔性元件产生。
根据另一实施例,所述柔性元件包括塑料材料,特别是热塑性材料、弹性体材料和/或热固性材料。
根据另一实施例,所述柔性元件包括高度闭孔材料。
特别地,该高度闭孔材料包括金属或金属泡沫。
此外,还提供了一种用于风力涡轮机的风力涡轮机叶片。该风力涡轮机叶片包括这样的复合材料。优选地,该风力涡轮机叶片包括弯曲部分,特别是弯曲表面,其中,所述复合材料与该弯曲部分表面接触和/或结合到该弯曲表面。
然而,所述复合材料可用于与风力涡轮机相关的任何其他应用中。
此外,还提供了一种风力涡轮机。该风力涡轮机包括这样的复合材料和/或这样的风力涡轮机叶片。
优选地,该风力涡轮机具有多个风力涡轮机叶片。“风力涡轮机”当前是指将风的动能转化成旋转能的装置,该旋转能可以再次通过该装置转化成电能。
此外,还提供了一种方法,其用于产生用于风力涡轮机叶片的复合材料,特别是这样的复合材料。所述方法包括以下步骤:a)提供多个刚性元件,b)提供多个柔性元件,c)将每个柔性元件布置在两个刚性元件之间,以及d)将每个柔性元件连接到两个刚性元件,使得所述刚性元件借助于所述柔性元件柔性地连接到彼此。
参考本发明的复合材料描述的实施例和特征比照适用于本发明的方法。
本发明的其他可能的实施方式或替代方案还包括本文未明确提及的上文所述或下文关于实施例所述的特征的组合。本领域技术人员还可以向本发明的最基本形式添加个别或孤立的方面和特征。
附图说明
结合附图,通过后续的描述和从属权利要求,本发明的其他实施例、特征和优点将变得显而易见,附图中:
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叶片的透视图;
图3示出了根据一个实施例的复合材料的透视图;
图4示出了根据另一实施例的复合材料的侧视图;
图5示出了根据另一实施例的复合材料的侧视图;
图6示出了图5的详细视图VI;以及
图7示出了用于产生根据图3的复合材料的方法的实施例的框图。
在附图中,除非另有指示,否则相同的附图标记表示相同或功能上等同的元件。
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,其连接到布置在机舱3内的发电机(未示出)。机舱3被布置在风力涡轮机1的塔架4的上端处。
转子2包括三个风力涡轮机叶片5。风力涡轮机叶片5被连接到风力涡轮机1的轮毂6。这种类型的转子2可具有例如范围从30米至160米或甚至更大的直径。风力涡轮机叶片5经受高的风荷载。同时,风力涡轮机叶片5需要重量轻。由于这些原因,现代风力涡轮机1中的风力涡轮机叶片5由纤维增强复合材料制成。其中,由于成本原因,玻璃纤维一般优于碳纤维是优选的。常常使用呈单向纤维垫(unidirectional fiber mat)形式的玻璃纤维。
图2示出了根据一个实施例的风力涡轮机叶片5。
风力涡轮机叶片5包括:空气动力学设计的部分7,其被成形为用于最佳地利用风能;以及叶片根部8,其用于将转子叶片5连接到轮毂6。此外,还设置复合材料9(示意性地示出),其增强风力涡轮机叶片5的叶片壳体10。
图3示出了根据一个实施例的复合材料9的透视图。
复合材料9包括多个刚性元件11和多个柔性元件12,其中,每个柔性元件12被布置在两个刚性元件11之间并且被连接到这两个刚性元件11,使得刚性元件12借助于柔性元件12柔性地连接到彼此。
优选地,刚性元件11具有弹性模量(elasticity module)E1(也称为第一弹性模量),并且柔性元件12具有弹性模量E2(也称为第二弹性模量),其中,弹性模量E1大于弹性模量E2。优选地,弹性模量E1为弹性模量E2的至少1.5倍、2倍、3倍或4倍。因此,刚性元件11比柔性元件12明显更刚硬。
柔性元件12仅借助于刚性元件11间接地连接到彼此。因此,当复合材料9均匀地展开、即不弯曲时,柔性元件12不附接到彼此,如图3中所示。刚性元件11和柔性元件12由不同的材料制成。特别地,所有刚性元件11都设置成相同。例如,所有柔性元件12也都设置成相同。优选地,每个柔性元件12被连接到一个刚性元件11'的侧面13,并且连接到另一刚性元件11''的另一侧面14。侧面13和另一侧面14面向彼此。在侧面13和侧面14之间设置间隙G。
柔性元件12完全填充刚性元件11之间的所有间隙G,使得由刚性元件11和柔性元件12形成的表面15是平坦的(even)。“完全”意味着直到刚性元件11的完整高度H。因此,柔性元件12被设置为刚性元件11之间的填充材料。
这具有如下优点,即:在安装复合材料9之后,可避免复合材料9中的不期望的空腔(也参见图4)。因此,在间隙G中可避免附加的填充材料,特别是叶片树脂。要注意的是,间隙G中的树脂可导致弱结构,这是因为树脂例如具有比柔性材料12低的刚性。
刚性元件12和柔性元件11是条形的。这意味着刚性元件11的长度L是刚性元件11的高度H和/或宽度W的若干倍,特别是至少10倍。因此,复合材料9在一个弯曲方向V上是柔性的,即围绕刚性元件11的纵向轴线A是柔性的。
优选地,刚性元件11由轻木制成。特别地,在这种情况下,复合材料9是柔性木板。可替代地,刚性元件11由刚性多孔泡沫(cellular foam)制成。例如,该刚性多孔泡沫可包括金属,特别是铝,和/或塑料材料,或者由上述材料制成。
每个刚性元件11具有矩形剖面形状,该矩形剖面形状特别是沿刚性元件11的纵向轴线A是不变的。因此,特别是借助于切割和/或锯切,可以简单地产生刚性元件11。当复合材料9均匀地展开和/或柔性元件12未变形时,柔性元件12也具有矩形剖面形状。
特别地,柔性元件12包括高度闭孔材料(highly closed cell material)。优选地,该高度闭孔材料包括金属或金属泡沫,特别是泡沫铝。附加地或替代地,柔性元件12可包括塑料材料,特别是热塑性材料、弹性体材料和/或热固性材料。
复合材料9被设置为模块16。这意味着刚性元件11被连接到一个模块16,该模块16可单独地管理为一个复合部件。因此,可提供模块16,其可通过组装工人的手力(handforce)来管理。模块16包括6个刚性元件11和5个柔性元件12。然而,这些数字可根据应用而变化。
优选地,模块16包括介于3个和20个之间、4个和15个之间或者4个和10个之间、特别是6个的刚性元件11。优选地,模块16借助于切割穿过(cut through)两个柔性元件12产生。刚性元件11和柔性元件11在垂直于轴线A延伸的方向B上交替。
图4示出了根据另一实施例的复合材料9的侧视图。
复合材料9形成平坦且适应性强的材料,该材料安置在叶片壳体10的弯曲表面17上并且在形状上适应于该弯曲表面17。在这种状态下,复合材料9增强叶片壳体10。如图4中所示,柔性元件12变形成使得刚性元件可适应于弯曲表面17。刚性元件11未变形。因此,复合材料9可适应于弯曲表面15而不会破裂。复合材料9可在其整个表面15(或另一个实施例中的表面23,未示出)上与表面17表面接触。例如,复合材料9可使用粘合剂来结合到表面17。
优选地,柔性元件12是可塑性或弹性变形的。特别地,柔性元件12具有比刚性元件11更大的可延展性。柔性元件的可延展性被选择成使得例如仅通过重力或通过将复合材料手动强制成弯曲表面17的几何形状来对复合材料产生可塑性(contourability),使得复合材料9由于塑性变形而保持这种形状。
如图4中所示,复合材料9围绕方向V弯曲。这样的柔性元件12的优点在于避免了刚性元件11之间的空腔。当使用厚(即,高度H增加)的刚性元件11时,这是特别重要的。
图5示出了复合材料9在设置为如图3中所示的可安装模块16之前的侧视图。
复合材料9被设置为半成品块18。与模块16对比,块18具有为高度H的若干倍、特别是至少3倍、5倍、7倍或10倍的高度H1。每个刚性元件21和/或柔性元件22都具有高度H1。
通过将块18切割成具有高度H的部分,可产生若干个模块16。优选地,块18借助于切割穿过两个柔性元件22产生。
图6示出了图5的详细视图VI。
柔性元件22例如借助于布置在面13和柔性元件22之间的粘合剂、特别是粘合剂层19以及布置在面14和柔性元件22之间的粘合剂、特别是粘合剂层20来连接到刚性元件21。
可替代地,刚性元件21可借助于热板焊接来连接到柔性元件22。在这种情况下,层19、20可被设置为熔化并且随后固化的区域。
因此,可实现复合材料9的足够强度。因此,可避免刚性元件11从柔性元件12的分离。
图7示出了用于产生根据图3的复合材料9或根据图2的风力涡轮机叶片5的方法的实施例的框图。
在第一步骤S1中,提供多个刚性元件21,其各自具有高度H1、宽度W和长度L。刚性元件21可由轻木提供,特别是借助于锯切来提供。可替代地,刚性元件21由刚性多孔泡沫提供。
此外,在步骤S2中,提供具有高度H1和长度L的多个柔性元件22。
在步骤S3中,每个柔性元件22被布置在两个刚性元件21之间。
在步骤S4中,每个柔性元件22被连接到两个刚性元件21,使得刚性元件21借助于柔性元件22柔性地连接到彼此。该连接步骤S4可借助于胶合或热板焊接来完成。特别地,步骤S3和S4作为一个步骤执行。在此阶段产生复合材料9。
在步骤S5中,复合材料9可被切割成使得提供具有宽度W1的块18(参见图6)。可替代地,执行步骤S3、S4,使得紧接在步骤S3和S4之后产生具有宽度W1的块18。在步骤S6中,块18被切割成具有高度H的模块16。在步骤S7中,模块16被连接到叶片壳体10的表面17,用于产生风力涡轮机叶片5。
尽管已根据优选实施例描述了本发明,但是对本领域技术人员而言显而易见的是,在所有实施例中修改都是可能的。

Claims (15)

1.一种用于风力涡轮机叶片(5)的复合材料(9),所述复合材料(9)包括多个刚性元件(11)和多个柔性元件(12),其中,每个柔性元件(12)被布置在两个刚性元件(11)之间并且连接到所述两个刚性元件(11),使得所述刚性元件(11)借助于所述柔性元件(12)柔性地连接到彼此。
2.根据权利要求1所述的复合材料,
其特征在于,所述复合材料(9)形成平坦的和/或适应性强的材料,所述材料构造成在安装时适应弯曲表面(17)。
3.根据权利要求1或2所述的复合材料,
其特征在于,所述柔性元件(12)完全填充所述刚性元件(11)之间的间隙(G),使得由所述刚性元件(11)和所述柔性元件(12)形成的表面(15)是平坦的。
4.根据权利要求1-3中任一项所述的复合材料,
其特征在于,所述刚性元件(11)和所述柔性元件(12)是条形的。
5.根据权利要求1-4中任一项所述的复合材料,
其特征在于,所述刚性元件(11)由轻木或刚性多孔泡沫制成。
6.根据权利要求1-5中任一项所述的复合材料,
其特征在于,每个刚性元件(11)具有矩形剖面形状,所述矩形剖面形状特别是沿所述刚性元件(11)的纵向轴线(A)是不变的。
7.根据权利要求1-6中任一项所述的复合材料,
其特征在于,所述柔性元件(12)是可塑性或弹性变形的。
8.根据权利要求1-7中任一项所述的复合材料,
其特征在于,所述柔性元件(12)借助于粘合剂(19、20)或热板焊接来连接到所述刚性元件(11)。
9.根据权利要求1-8中任一项所述的复合材料,
其特征在于,所述刚性元件(11)具有第一弹性模量(E1),并且所述柔性元件(12)具有第二弹性模量(E2),并且其中,所述第一弹性模量(E1)大于所述第二弹性模量(E2)。
10.根据权利要求1-9中任一项所述的复合材料,
其特征在于,介于3个和20个之间、4个和15个之间或4个和10个之间、特别是3个、4个、5个、6个或7个的刚性元件(11)被连接以形成单个模块(16),所述模块(16)能够作为单件处理。
11.根据权利要求1-10中任一项所述的复合材料,
其特征在于,所述柔性元件(12)包括塑料材料,特别是热塑性材料、弹性体材料和/或热固性材料。
12.根据权利要求1-11中任一项所述的复合材料,
其特征在于,所述柔性元件(12)包括高度闭孔材料。
13.一种用于风力涡轮机(1)的风力涡轮机叶片(5),包括根据权利要求1-12中任一项所述的复合材料(9)。
14.一种风力涡轮机(1),其包括根据权利要求1-12中任一项所述的复合材料(9)和/或根据权利要求13所述的风力涡轮机叶片(5)。
15.一种用于产生用于风力涡轮机叶片(5)的特别是根据权利要求1-12中任一项所述的复合材料(9)的方法,所述方法包括以下步骤:
a)提供(S1)多个刚性元件(21),
b)提供(S2)多个柔性元件(22),
c)将每个柔性元件(22)布置(S3)在两个刚性元件(21)之间,以及
d)将每个柔性元件(22)连接(S4)到两个刚性元件(21),使得所述刚性元件(21)借助于所述柔性元件(22)柔性地连接到彼此。
CN201910666137.3A 2018-07-23 2019-07-23 复合材料、风力涡轮机叶片、风力涡轮机和用于产生复合材料的方法 Pending CN110748452A (zh)

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