CN111655448A - 用于制造转子叶片的外蒙皮的方法 - Google Patents
用于制造转子叶片的外蒙皮的方法 Download PDFInfo
- Publication number
- CN111655448A CN111655448A CN201880087217.7A CN201880087217A CN111655448A CN 111655448 A CN111655448 A CN 111655448A CN 201880087217 A CN201880087217 A CN 201880087217A CN 111655448 A CN111655448 A CN 111655448A
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- CN
- China
- Prior art keywords
- skin layer
- outer skin
- rotor blade
- combination
- inner skin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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Abstract
一种用于制造转子叶片的外蒙皮的方法包括由一种或多种树脂或纤维材料中的至少一种的第一组合来形成外蒙皮的外蒙皮层。方法还包括由一种或多种树脂或纤维材料中的至少一种的第二组合来形成外蒙皮的内蒙皮层。更特别地,第一组合和第二组合是不同的。此外,方法包括将外蒙皮层和内蒙皮层以堆叠构造布置在一起。另外,方法包括将外蒙皮层和内蒙皮层连结在一起以形成外蒙皮。
Description
技术领域
本公开内容大体上涉及风力涡轮转子叶片,且更特别地涉及一种用于制造风力涡轮转子叶片的外蒙皮的方法。
背景技术
风力被认为是目前可获得的最清洁、最环境友好的能源中的一种,且风力涡轮在该方面获得了增加的关注。现代的风力涡轮典型地包括塔架、发电机、齿轮箱、机舱,以及一个或多个转子叶片。转子叶片使用已知的翼型(foil)原理来获取风的动能。转子叶片传送呈旋转能形式的动能,以便转动轴,该轴将转子叶片联接到齿轮箱(或如果不使用齿轮箱,直接联接到发电机)。发电机然后将机械能转换成电能,该电能可部署至公用网。
转子叶片大体上包括吸力侧壳和压力侧壳,该壳典型地使用模制过程来形成,该壳沿叶片前缘和后缘在结合线处结合在一起。此外,压力壳和吸力壳相对轻量,且具有不构造成承受在操作期间施加在转子叶片上的弯矩和其它负载的结构性质(例如,刚度、抗屈曲性和强度)。因此,为增加转子叶片的刚度、抗屈曲性和强度,主体壳典型地使用一个或多个结构构件(例如,在它们之间构造有抗剪腹板的相反翼梁帽)来增强,该结构构件接合壳半部的内部压力侧表面和吸力侧表面。
翼梁帽典型地由各种材料(包括但不限于玻璃纤维层压复合物和/或碳纤维层压复合物)构成。转子叶片的壳大体上通过在壳模具中堆叠纤维织物的外层和内层来围绕叶片的翼梁帽构建。层然后典型地灌注(infuse)在一起,例如用热固性树脂。
用于制造转子叶片的方法还可包括分段地形成转子叶片。然后可组装叶片节段来形成转子叶片。例如,一些现代的转子叶片,诸如在2015年6月29日提交的且题为“ModularWind Turbine Rotor Blades and Methods of Assembling Same(模块化风力涡轮转子叶片和组装其的方法)”的编号为14/753,137的美国专利申请中描述的那些叶片,具有模块化板构造,该申请通过引用以其整体结合于本文中。因此,模块化叶片的各个叶片构件可基于叶片构件的作用和/或位置由不同的材料构成。
对于常规的转子叶片,形成叶片壳的外蒙皮典型地由经由单种树脂材料连结在一起的纤维织物构成。然而,在某些情况下,为各种应用定制用来形成外蒙皮的材料可为有益的。
如此,本公开内容涉及用于制造带有不同基质树脂和/或聚合物添加层的风力涡轮转子叶片的外蒙皮的方法。
发明内容
本发明的方面和优点将在以下描述中部分地阐述,或可从描述中清楚,或可通过实施本发明来获悉。
在一方面,本公开内容涉及一种用于制造转子叶片的外蒙皮的方法。方法包括由一种或多种树脂和/或纤维材料的第一组合来形成外蒙皮的外蒙皮层。外蒙皮层对应于转子叶片的外表面。方法还包括由一种或多种树脂和/或纤维材料的第二组合来形成外蒙皮的内蒙皮层。内蒙皮层对应于转子叶片的内表面。更特别地,材料的第一组合和第二组合是不同的。此外,方法包括将外蒙皮层和内蒙皮层以堆叠构造布置在一起。另外,方法包括将外蒙皮层和内蒙皮层连结在一起以形成转子叶片的外蒙皮。
在一个实施例中,方法还可包括基于涂料(pigment)增加、紫外线(UV)防护、热防护、腐蚀防护和/或防止结冰来定制第一组合。如此,第一组合和/或第二组合的树脂可包括热塑性材料(诸如非晶态热塑性材料)和/或可选的纤维材料(诸如玻璃纤维、碳纤维、聚合物纤维、木纤维、竹纤维、陶瓷纤维、纳米纤维或金属纤维)。
在另一实施例中,方法可包括基于兼容性、结合效率、焊接效率和/或结构性能(例如刚度)来定制第二组合。因此,第二组合的树脂可包括热塑性材料或热固性材料。此外,第二组合的纤维材料可包括玻璃纤维、碳纤维、聚合物纤维、木纤维、竹纤维、陶瓷纤维、纳米纤维或金属纤维。
在特定的实施例中,方法可包括由热塑性材料形成外蒙皮层或内蒙皮层中的一个,以及由热固性材料形成外蒙皮层或内蒙皮层中的另一个。在此类实施例中,由热塑性材料形成的蒙皮层可具有能够挠曲以允许蒙皮层在连结期间真空顺应于模具的厚度。
在另外的实施例中,方法可包括在外蒙皮层和内蒙皮层中的一者或两者中使一定量的热塑性材料偏置,以便产生树脂富集区域和树脂缺乏区域。
在额外的实施例中,方法可包括在外蒙皮层与内蒙皮层之间放置至少一个结构层。例如,在此类实施例中,结构层可包括拉挤物、一个或多个金属层、一个或多个玻璃层、木、泡沫、结构泡沫和/或纤维材料。
在若干实施例中,方法还可包括经由带压制、灌注、真空成型或热成型中的至少一种来将第一外蒙皮层和第二外蒙皮层连结在一起。
在另一实施例中,方法可包括在将外蒙皮层和内蒙皮层连结在一起之前,使一个或多个次级构件结合到外蒙皮层和/或内蒙皮层中。在此类实施例中,次级构件可包括一个或多个传感器、传感器线、传导元件或材料、自修复元件、加热元件、电磁屏蔽件、一个或多个通道、焊接条和/或焊接网。
在还另外的实施例中,使一个或多个次级构件结合到外蒙皮层、内蒙皮层或至少一个结构层中的至少一个中的步骤可包括3D打印一个或多个次级构件,手动放置一个或多个次级构件,经由机器人系统自动放置一个或多个次级构件,或灌注一个或多个次级构件。在另外的实施例中,方法可包括经由光投影系统(例如,诸如激光系统)来对准次级构件。在又一实施例中,方法可包括将至少一个结构构件打印和/或沉积到连结的外蒙皮层和/或内蒙皮层上。
在另一方面,本公开内容涉及一种用于风力涡轮的转子叶片的转子叶片板。转子叶片板包括由一种或多种树脂和/或纤维材料的第一组合所形成的外蒙皮层,该外蒙皮层形成转子叶片板的外表面。转子叶片板还包括与外蒙皮层相邻布置的内蒙皮层。内蒙皮层由一种或多种树脂和/或纤维材料的第二组合来形成。此外,材料的第一组合和第二组合是不同的,以便实现板的内表面和外表面的期望特性。而且,外蒙皮层和内蒙皮层形成转子叶片板的翼型件形状的至少一部分。转子叶片板还可包括如本文中描述的额外特征中的任一个。
参照以下描述和所附权利要求书,本发明的这些和其它特征、方面和优点将变得更好理解。结合于该说明书中且构成该说明书的一部分的附图示出本发明的实施例,且连同描述一起用来解释本发明的原理。
附图说明
针对本领域普通技术人员的本发明的完整且开放(enabling)的公开内容(包括其最佳模式)在参照附图的说明书中阐述,在附图中:
图1示出根据本公开内容的风力涡轮的一个实施例的透视图;
图2示出根据本公开内容的风力涡轮的转子叶片的一个实施例的透视图;
图3示出图2的模块化转子叶片的分解视图;
图4示出根据本公开内容的模块化转子叶片的前缘节段的一个实施例的截面视图;
图5示出根据本公开内容的模块化转子叶片的后缘节段的一个实施例的截面视图;
图6示出根据本公开内容的图2的模块化转子叶片沿线6-6的截面视图;
图7示出根据本公开内容的图2的模块化转子叶片沿线7-7的截面视图;
图8示出根据本公开内容的用于制造转子叶片的外蒙皮的方法的一个实施例的流程图;
图9示出经由根据本公开内容的制造方法所形成的外蒙皮的一个实施例的侧视图;
图10示出根据本公开内容的放置在模具中的外蒙皮层和内蒙皮层的一个实施例的侧视图;
图11示出根据本公开内容的内蒙皮层的一个实施例的顶视图;
图12示出根据本公开内容的外蒙皮层的一个实施例的顶视图;以及
图13示出根据本公开内容的转子叶片板模具的一个实施例的侧视图;
图14示出根据本公开内容的用于形成外蒙皮层和内蒙皮层的双带压制处理的一个实施例的示意图。
具体实施方式
现在将详细地参照本发明的实施例,其一个或多个示例在图中示出。每个示例提供作为本发明的解释,不是本发明的限制。实际上,对本领域技术人员将显而易见的是,在不脱离本发明的范围或精神的情况下,可在本发明中作出各种修改和变型。例如,示出或描述为一个实施例的部分的特征可与另一实施例使用,以产生还另外的实施例。因此,意图的是,本发明覆盖如落入所附权利要求书和其等同物的范围内的此类修改和变型。
大体上,本公开内容涉及用于使用多种材料组合来制造用于风力涡轮转子叶片的外蒙皮的方法。在层压件内使用不同的基质和/或不同的织物可用来优化打印结构的结合,同时在外侧表面上提供其它期望的特征。例如,外蒙皮层可包括提供UV防护、去冰(iceophobic)防护和/或腐蚀防护的材料。此外,拉挤物和/或重玻璃可添加于蒙皮层中间以用于改进强度,但其也可在预期的过程中成功地真空成型(即使板较厚且较硬)。在此类构造中,外蒙皮最大限度地减少所需要的打印结构的量。传感器(诸如光纤)和传导元件或材料也可结合到层压件中。因此,本文中描述的方法提供现有技术中不存在的许多优点。例如,本公开内容的方法提供容易定制叶片外蒙皮以具有各种曲率、空气动力学特性、强度、刚度等的能力。
现在参照图,图1示出根据本公开内容的风力涡轮10的一个实施例。如示出的,风力涡轮10包括塔架12,其上安装有机舱14。多个转子叶片16安装到转子毂18,转子毂18继而连接到主凸缘,该主凸缘转动主转子轴。风力涡轮功率生成和控制构件容纳在机舱14内。图1的视图仅提供用于说明性目的来使本发明置于示例性的使用领域中。应了解的是,本发明不限于任何特定类型的风力涡轮构造。另外,本发明不限于供风力涡轮使用,而是可用于具有转子叶片的任何应用中。
现在参照图2和图3,示出根据本公开内容的转子叶片16的各种视图。如示出的,所示出的转子叶片16具有分段或模块化构造。还应理解的是,转子叶片16可包括本领域中现在已知或以后开发的任何其它合适的构造。如示出的,模块化转子叶片16包括至少部分地由热固性和/或热塑性材料构成的主叶片结构15以及与主叶片结构15构造的至少一个叶片节段21。更特别地,如示出的,转子叶片16包括多个叶片节段21。叶片节段21也可至少部分地由热固性和/或热塑性材料构成。
如本文中描述的热塑性转子叶片构件和/或材料大体上包含性质上可逆的塑料材料或聚合物。例如,热塑性材料典型地在加热到某个温度时变得易曲折或可模制且在冷却时回复到较刚性的状态。此外,热塑性材料可包括非晶态热塑性材料和/或半晶态热塑性材料。例如,一些非晶态热塑性材料大体上可包括但不限于苯乙烯、乙烯基、纤维素、聚酯、丙烯酸、聚砜和/或酰亚胺。更特别地,示例性非晶态热塑性材料可包括聚苯乙烯、丙烯腈-丁二烯-苯乙烯(ABS)、聚甲基丙烯酸甲酯(PMMA)、糖化(glycolised)聚对苯二甲酸乙二醇酯(PET-G)、聚碳酸酯、聚醋酸乙烯酯、非晶态聚酰胺、聚氯乙烯(PVC)、聚偏二氯乙烯、聚氨酯,或任何其它合适的非晶态热塑性材料。另外,示例性半晶态热塑性材料大体上可包括但不限于聚烯烃、聚酰胺、含氟聚合物、丙烯酸乙酯、聚酯、聚碳酸酯和/或缩醛。更特别地,示例性半晶态热塑性材料可包括聚对苯二甲酸丁二醇酯(PBT)、聚对苯二甲酸乙二醇酯(PET)、聚丙烯、聚苯硫醚、聚乙烯、聚酰胺(尼龙)、聚醚酮,或任何其它合适的半晶态热塑性材料。例如,在一个实施例中,可使用被改性以具有慢结晶速率的半晶态热塑性树脂。另外,也可使用非晶态和半晶态聚合物的共混物。
此外,如本文中描述的热固性构件和/或材料大体上包含性质上不可逆的塑料材料或聚合物。例如,热固性材料一旦固化,不能容易地改造或回复到液态。如此,在初始形成之后,热固性材料大体上耐热、腐蚀和/或蠕变。示例热固性材料大体上可包括但不限于一些聚酯、一些聚氨酯、酯类、环氧树脂,或任何其它合适的热固性材料。
另外,如提到的,如本文中描述的热塑性和/或热固性材料可选地可用纤维材料来增强,该纤维材料包括但不限于玻璃纤维、碳纤维、聚合物纤维、木纤维、竹纤维、陶瓷纤维、纳米纤维、金属纤维或类似物或其组合。另外,纤维的方向可包括多轴、单向、双轴、三轴或任何其它另一合适的方向和/或其组合。此外,取决于对应叶片构件中所需要的刚度、叶片构件在转子叶片16中的区域或位置和/或构件的期望可焊接性,纤维含量可不同。
更特别地,如示出的,主叶片结构15可包括以下的任何一个或其组合:预成型的叶片根部区段20,预成型的叶片末端区段22,一个或多个连续翼梁帽48、50、51、53,一个或多个抗剪腹板35(图6-7),固定到叶片根部区段20的额外结构构件52,和/或转子叶片16的任何其它合适的结构构件。此外,叶片根部区段20构造成安装或以其它方式固定到转子18(图1)。另外,如图2中示出的,转子叶片16限定翼展23,翼展23等于叶片根部区段20与叶片末端区段22之间的总长度。如图2和图6中示出的,转子叶片16还限定翼弦25,翼弦25等于转子叶片16的前缘24与转子叶片16的后缘26之间的总长度。如大体上理解的,随着转子叶片16从叶片根部区段20延伸到叶片末端区段22,翼弦25相对于翼展23大体上可在长度上不同。
特别地参照图2-4,具有任何合适大小和/或形状的任何数量的叶片节段21或板大体上可沿纵向轴线27在大体上沿翼展的方向上布置在叶片根部区段20与叶片末端区段22之间。因此,叶片节段21大体上用作转子叶片16的外壳/覆盖物,且可限定大致空气动力学的轮廓,诸如通过限定对称的或弧形的翼型件形截面。在额外的实施例中,应理解的是,叶片16的叶片节段部分可包括本文中描述的节段的任何组合,且不限于如所描绘的实施例。另外,叶片板21可包括以下的任何一个或其组合:压力侧节段44和/或吸力侧节段46(图2和图3)、前缘节段40和/或后缘节段42(图2-6)、无接头节段、单接头节段、多接头叶片节段、J形叶片节段或类似物。
更特别地,如图4中示出的,前缘节段40可具有前压力侧表面28和前吸力侧表面30。类似地,如图5中示出的,后缘节段42中的每个可具有后压力侧表面32和后吸力侧表面34。因此,前缘节段40的前压力侧表面28和后缘节段42的后压力侧表面32大体上限定转子叶片16的压力侧表面。类似地,前缘节段40的前吸力侧表面30和后缘节段42的后吸力侧表面34大体上限定转子叶片16的吸力侧表面。另外,如图6中特别示出的,前缘节段40和后缘节段42可在压力侧接缝36和吸力侧接缝38处连结。例如,叶片节段40、42可构造成在压力侧接缝36和/或吸力侧接缝38处重叠。此外,如图2中示出的,相邻叶片节段21可构造成在接缝54处重叠。因此,在叶片节段21至少部分地由热塑性材料构成的情况下,相邻叶片节段21可沿接缝36、38、54焊接在一起,这将在本文中更详细地论述。备选地,在某些实施例中,转子叶片16的各个节段可经由构造在重叠的前缘节段40和后缘节段42和/或重叠的相邻前缘节段40或后缘节段42之间的粘合剂(或机械紧固件)来固定在一起。
在特定的实施例中,如图2-3和图6-7中示出的,叶片根部区段20可包括与其一起灌注的一个或多个纵向延伸的翼梁帽48、50。例如,叶片根部区段20可根据2015年6月29日提交的题为“Blade Root Section for a Modular Rotor Blade and Method ofManufacturing Same(用于模块化转子叶片的叶片根部区段和制造其的方法)”的编号为14/753,155的美国申请来构造,该申请通过引用以其整体结合于本文中。
类似地,叶片末端区段22可包括与其一起灌注的一个或多个纵向延伸的翼梁帽51、53。更特别地,如示出的,翼梁帽48、50、51、53可构造成抵靠转子叶片16的叶片节段21的相反内表面来接合。此外,叶片根部翼梁帽48、50可构造成与叶片末端翼梁帽51、53对准。因此,翼梁帽48、50、51、53大体上可设计成在风力涡轮10的操作期间控制在大体上沿翼展的方向(平行于转子叶片16的翼展23的方向)上作用在转子叶片16上的弯曲应力和/或其它负载。另外,翼梁帽48、50、51、53可设计成承受在风力涡轮10的操作期间出现的沿翼展的压缩。此外,翼梁帽48、50、51、53可构造成从叶片根部区段20延伸到叶片末端区段22或其一部分。因此,在某些实施例中,叶片根部区段20和叶片末端区段22可经由它们相应的翼梁帽48、50、51、53来连结在一起。
另外,翼梁帽48、50、51、53可由任何合适的材料(例如热塑性或热固性材料或其组合)构成。此外,翼梁帽48、50、51、53可由热塑性或热固性树脂拉挤成。如本文中使用的,用语“拉挤”、“拉挤物”或类似物大体上包含增强材料(例如纤维或者织造或编织股线),其用树脂浸渍且被拉动穿过固定模,使得树脂固化或经历聚合。如此,制造拉挤部件的过程典型地以产生具有恒定截面的复合零件的复合材料的连续过程为特征。因此,预固化复合材料可包括由增强热固性或热塑性材料构成的拉挤物。此外,翼梁帽48、50、51、53可由相同的预固化复合物或不同的预固化复合物来形成。另外,拉挤构件可由粗纱产生,该粗纱大体上包含长且窄束的纤维,该纤维不组合,直到由固化树脂所连结。
参照图6-7,一个或多个抗剪腹板35可构造在一个或多个翼梁帽48、50、51、53之间。更特别地,抗剪腹板35可构造成增加叶片根部区段20和/或叶片末端区段22中的刚性。此外,抗剪腹板35可构造成封闭(close out)叶片根部区段20。
另外,如图2和图3中示出的,额外的结构构件52可固定到叶片根部区段20,且在大体上沿翼展的方向上延伸,以便向转子叶片16提供另外的支承。例如,结构构件52可根据2015年6月29日提交的题为“Structural Component for a Modular Rotor Blade(用于模块化转子叶片的结构构件)”的编号为14/753,150的美国申请来构造,该申请通过引用以其整体结合于本文中。更特别地,结构构件52可在叶片根部区段20与叶片末端区段22之间延伸任何合适的距离。因此,结构构件52构造成为转子叶片16提供额外的结构支承以及为如本文中描述的各个叶片节段21提供可选的安装结构。例如,在某些实施例中,结构构件52可固定到叶片根部区段20,且可延伸预定的沿翼展的距离,使得前缘节段40和/或后缘节段42可安装到其。
现在参照图8,本公开内容涉及用于制造转子叶片16的外蒙皮56和/或转子叶片板21的方法以及经由此类方法制造的转子叶片板21。更特别地,本文中描述的方法包含在转子叶片板21的外蒙皮56的内蒙皮层60和外蒙皮层58内的多种材料组合。在层压件内使用不同的基质和/或不同的织物可用来优化打印结构与其的结合,同时在板21的外侧表面上提供其它期望的特征。
例如,如102处示出的,方法100包括由一种或多种树脂和/或纤维材料的第一组合来形成外蒙皮56的外蒙皮层58。更特别地,在一个实施例中,方法100可包括基于外蒙皮56的外表面的某些期望特性(诸如涂料增加(即,减少和/或消除对涂抹的需要)、紫外线(UV)防护、热防护、腐蚀防护或抗腐蚀性、防止结冰和/或其它期望的性质)来定制树脂和/或纤维材料的第一组合。如此,树脂和/或纤维材料的第一组合可包括热塑性材料,诸如,可选地用玻璃纤维、碳纤维、聚合物纤维、木纤维、竹纤维、陶瓷纤维、纳米纤维和/或金属纤维来增强的非晶态热塑性材料。
类似地,如104处示出的,方法100还包括由一种或多种树脂和/或纤维材料的第二组合来形成外蒙皮的内蒙皮层60。更特别地,材料的第一组合和第二组合可不同,以便适应每个表面62、64的某些期望特性。因此,在一个实施例中,热塑性玻璃纤维板可在外侧上由一种基质制成且在内部上由另一基质制成。如此,在另一实施例中,方法100可包括基于兼容性、与打印特征的结合效率、焊接效率(例如将多个板21焊接在一起和/或将构件/特征焊接到板21)和/或结构性能(例如刚度)来定制树脂和/或纤维材料的第二组合。如本文中使用的,“兼容性”大体上是指对应蒙皮层之间的兼容性以及与打印网结构的兼容性。在使用热塑性塑料时,相同的热塑性可用于每层,然而,也存在一些不同的热塑性塑料可热焊接在一起。
第二组合的树脂可包括热塑性材料或热固性材料。此外,此类树脂可选地可用第二组合的纤维材料来增强。包括但不限于玻璃纤维、碳纤维、聚合物纤维、木纤维、竹纤维、陶瓷纤维、纳米纤维或金属纤维。热塑性材料对于热塑性焊接是特别有用的,而热固性材料允许更多的与其它热固性构件结合的选择。
另外,如图9和图10中示出的,转子叶片板21的外蒙皮层58和内蒙皮层60可为弯曲的。在此类实施例中,方法100可包括形成外蒙皮层58和内蒙皮层60的曲率。此类形成可包括提供一个或多个大体上平的纤维增强蒙皮层,迫使外蒙皮层58和内蒙皮层60为对应于期望轮廓的期望形状,以及在(例如网结构68的)打印期间将外蒙皮层58和内蒙皮层60保持在期望的形状。如此,当蒙皮层58、60在打印后释放时,外蒙皮层58和内蒙皮层60大体上保持它们期望的形状。
例如,在一个实施例中,方法100可包括在外蒙皮层58和内蒙皮层60中的一者或两者中使一定量的热塑性材料偏置,以便产生树脂富集区域和树脂缺乏区域。在此类实施例中,内蒙皮层60可在内侧表面64上用更多(或甚至更少)的基质树脂材料来形成,以促进与打印结构构件(例如,诸如图10中示出的网结构68)的结合。如此,本文中描述的方法100可包括将至少一个结构构件打印和/或沉积到所连结的外蒙皮层和/或内蒙皮层上。本文中描述的网结构68以及各个其它转子叶片构件可使用三维(3D)打印或任何合适形式的增材制造来形成。如此,内蒙皮层60和外蒙皮层58可制造成优化此类结构直接与其的结合。因此,树脂富集表面可促进期望接口处的热焊接(例如,3D打印结构和/或板对板的接头)。相反,树脂缺乏区域促进3D打印结构与层压件纤维材料的改进的集成。更特别地,图11示出内蒙皮层60的一个实施例的顶视图,特别地示出具有树脂富集区域74的内表面64,该区域74特意放置在网结构68所期望打印处的位置中。
如本文中使用的,3D打印大体上理解成包含用来合成三维物体的过程,其中连续的材料层在计算机控制下(例如使用具有一个或多个挤出器的计算机数字控制(CNC)装置或3D打印机)形成以产生物体。如此,几乎任何大小和/或形状的物体可由数字模型数据产生。还应理解的是,本公开内容的方法不限于3D打印,而是还可包含多于三个自由度,使得打印技术不限于打印堆叠的二维层,而是还能够打印弯曲的形状。
在特定的实施例中,方法100可包括由热塑性材料形成外蒙皮层58或内蒙皮层60中的一个,以及由热固性材料形成外蒙皮层58或内蒙皮层60中的另一个。在额外的实施例中,方法100可包括使蒙皮层厚度和/或纤维含量以及纤维定向不同。如此,在一个实施例中,由热塑性材料形成的蒙皮层可具有能够挠曲以允许蒙皮层在连结期间真空顺应于模具的厚度。
往回参照图8,如106处示出的,方法100包括将外蒙皮层58和内蒙皮层60以堆叠构造布置在一起。例如,如图9和图10中示出的,蒙皮层58、60一旦形成,方法100可包括将蒙皮层58、60放置到转子叶片板21的模具70中彼此顶上。
在额外的实施例中,如示出的,方法100还可包括在外蒙皮层58与内蒙皮层60之间放置至少一个结构层66。如此,因为可形成更厚的蒙皮层,加强转子叶片16和/或各个板21所需要的3D打印结构的量可减少。例如,在此类实施例中,结构层66可包括拉挤物、一个或多个金属层、一个或多个玻璃层和/或纤维材料。更特别地,在特定的实施例中,拉挤物和/或重玻璃可添加于外蒙皮层58与内蒙皮层60中间,以形成改进的结构,即使板较厚且较硬,该结构仍可在预期的过程中成功地真空成型。在此类实施例中,结构层66构造成最大限度地减少所需要的打印结构(例如网结构68)的量。在额外的实施例中,也可仅通过添加更多的织物层来形成更厚的蒙皮层。
在另一实施例中,方法100可包括在将外蒙皮层58和内蒙皮层60连结在一起之前,使一个或多个次级构件72结合到外蒙皮层58和/或内蒙皮层60中。例如,如图12中示出的,示出外蒙皮层60的外表面62的一个实施例的顶视图,特别地示出形成引导到外蒙皮56中的各个次级构件72。可使用任何合适的方法(诸如3D打印、手动放置、与外蒙皮56灌注等)来使此类构件72结合到外蒙皮层58或内蒙皮层60中。
在此类实施例中,如图12中示出的,次级构件72可包括传感器系统,该传感器系统具有一个或多个传感器76(例如,诸如光纤传感器、探头、声学传感器等)、传感器线78、电传导材料75或元件(例如,诸如碳、碳纤维填充物和/或任何合适的雷电接收器)、辐射吸收性材料、自修复元件77(例如磁或电吸引的树脂袋)、加热元件80、电磁屏蔽件82、一个或多个通道、支承件或管道和/或一个或多个焊接特征84(例如用于供热塑性焊接、电阻/感应焊接、化学焊接和/或激光/红外类型焊接所使用的焊接条或网)。
在额外的实施例中,可在打印过程期间使传感器系统的一个或多个构件结合到网结构68和/或外蒙皮56中。在此类实施例中,传感器系统可为与网结构68布置和/或直接结合到外蒙皮层58或内蒙皮层60中的表面压力测量系统。如此,打印结构68和/或外蒙皮层58或内蒙皮层60可制造成包括容易安装传感器系统所需要的一系列的管道/通道。此外,打印结构68和/或外蒙皮层58或内蒙皮层60也可在其中提供一系列的孔来用于接收系统的连接部。因此,通过将各个结构打印到网结构68和/或蒙皮56中以容纳传感器76、用作静压端口和/或用作直接延伸到外叶片蒙皮层的管道来简化制造过程。此类系统还可允许使用测压孔(pressure tap)来用于风力涡轮10的闭环控制。
在还另外的实施例中,如图13中示出的,模具70可包括某些标记79(诸如凸(positive)标记),该标记构造成在制造期间在蒙皮中产生小的凹坑。此类标记79允许容易地在相关联的传感器所需要的精确位置中机加工孔。另外,额外的传感器系统可结合到网结构68和/或外蒙皮层58或内蒙皮层60中,以提供空气动力学或声学测量,以便允许闭环控制或原型测量。
另外,本文中描述的加热元件80可为围绕叶片前缘分布的齐平表面安装的加热元件。此类加热元件80允许通过将温度/对流热传递与流速和驻点相关来确定叶片上的攻角。此类信息对于涡轮控制是有用的,且可简化测量过程。应理解的是,此类加热元件80也可以以额外的方式结合到外蒙皮层58或内蒙皮层60中,且不需要齐平地安装在其中。
仍参照次级材料,本文中描述的传导材料可结合或以其它方式沉积到外蒙皮层58或内蒙皮层60中或其上,以向其提供以下益处中的一个或多个:除冰、雷电(lighting)防护、自修复、为传感器76供应功率,或用作传感器本身。大体上,风力涡轮转子叶片中的传导材料应连接到其雷电防护系统,因为不这样做引起雷电损坏(由于冲击在没有地方来放出能量的情况下附加到传导材料)。如此,本文中描述的传导材料可以选择性地沉积到外蒙皮56上且用于电阻热塑性焊接,以便形成到雷电防护系统的连接。
在此类实施例中,CNC装置可以选择性地使用传导树脂以从焊接条或从焊接接头处打印的传导区域的它本身的区域沿外蒙皮56到用于连接到雷电防护系统的连接点来打印大量的传导迹线。打印的迹线也可过渡到打印的连接部,以允许使用传导杆来组装到打印的容座中。相同的打印传导材料可用来连续地打印焊接条、迹线、用于金属线缆的容座、金属条等。金属装置也可通过在该部分的顶部上套印来封装到容座中。另外,在外蒙皮58真空成型之前,可首先将传导迹线网直接打印到模具。在此类实施例中,传导迹线将保留在外蒙皮层58的外表面上。铺带头也可用来将基于线的热塑性带首先直接放置到模具,或放置到内蒙皮层58的内侧表面,以还用作到雷电防护系统的迹线。
如提到的,对于除了热塑性焊接之外的焊接过程,诸如激光/红外焊接,可向蒙皮层58、60添加涂料(诸如白色Ti02)来吸收辐射能。而且,非传导但吸收性的材料可允许热塑性焊接到外蒙皮56,而不必将传导材料放在未连接到雷电防护系统的转子叶片16中和招致雷电损坏风险。
对于感应焊接,3D打印机可描画传导材料的互连网。在不互连的情况下,对交变磁场的响应将不生成热量。相反,电阻焊接可不需要互连网图案。此外,在感应焊接中,玻璃纤维典型地不从感应源生成加热响应;因此,最大限度地减少大部分基质或树脂的热降解。而且,玻璃纤维将热量集中在所需要处的焊接接头处。
为结合本文中描述的焊接网84,可在模具表面中形成一个或多个凹部,且可在形成蒙皮层58、60之前将焊接网直接施加到模具。另外,可在形成之前将焊接网84施加到平的玻璃纤维板。此外,任何合适的材料可用来形成焊接网84。例如,对于感应焊接,焊接网84可包括用于加热的碳纤维热塑性条和/或交叉层纤维。对于在焊接接头的接缝处的非空气动力学表面,真空成型可用来施加凹入的区域和/或证示线以准确地定位焊接网84。
传导元件(其可包括传导条)可为有意多孔的线,以防止在形成蒙皮层58、60时堵塞模具中的真空孔,从而允许暂时保持条,同时还允许将初级热塑性玻璃纤维层压件向下真空拉动于条的顶部上。在此类实施例中,CNC装置的挤出器可配备有金属线或窄线网的转轴。如此,金属线可在挤出器中馈送通过熔体且结合到打印的路中。备选地,线或网可由单独的头来施加且由打印的路所覆盖。
另外,如提到的,次级材料或构件可包括一个或多个限定的通道,该通道构造成接收与外蒙皮56保持紧密接触来使转子叶片16接地的导体。在此类实施例中,带有沿转子叶片16的长度周期性放置的引线(lead)的中心导体可用来连接到雷电防护系统的传导元件中的任一个。
对于转子叶片的修理,某些次级材料可包括中心传导层(也可包括于蒙皮层58、60之间),且/或可在树脂内包括一定量的炭黑涂料,以允许操作者根据需要施加局部热量的能力。
在某些情况下,次级材料或构件中的一些可需要位置准确度,使得构件放置在最终叶片组件中的正确位置中。因此,如图10中示出的,方法100可包括经由对准系统86来对准次级构件72。例如,如示出的,对准系统86可构造在模具70的上方,以便向操作者提供关于在哪里定位本文中描述的次级构件72的细节。更特别地,在某些实施例中,对准系统86可为自动的机器人系统或光投影系统(例如,带有上方激光照明以向操作者示出在哪里放置次级构件72的激光系统)。另外,方法100包括确保嵌入的次级构件72将在连结过程期间耐受变形和/或加热。
往回参照图8,如108处示出的,方法100包括将外蒙皮层58和内蒙皮层60连结在一起以形成外蒙皮56。例如,在某些实施例中,方法100可包括经由带压制、灌注、真空成型、压力成型、热成型或任何其它合适的连结过程来将第一外蒙皮层58和第二外蒙皮层60连结在一起。更特别地,如图10中示出的,外蒙皮层58和内蒙皮层60可放置到模具70中且经由真空灌注来连结在一起。备选地,如图14中示出的,外蒙皮层58和内蒙皮层60可通过双带压制过程来连结在一起以形成外蒙皮56。
该书面描述使用示例来公开本发明(包括最佳模式),且还使本领域的任何技术人员能够实施本发明,包括制作和使用任何装置或系统以及执行任何结合的方法。本发明的可申请专利的范围由权利要求书限定,且可包括本领域技术人员想到的其它示例。如果此类其它示例包括不异于权利要求书的字面语言的结构元件,或如果它们包括带有与权利要求书的字面语言非实质性差异的等同结构元件,此类其它示例意在处于权利要求书的范围内。
Claims (20)
1.一种用于制造转子叶片的外蒙皮的方法,所述方法包括:
由一种或多种树脂或纤维材料中的至少一种的第一组合来形成所述外蒙皮的外蒙皮层,所述外蒙皮层对应于所述转子叶片的外表面;
由一种或多种树脂或纤维材料中的至少一种的第二组合来形成所述外蒙皮的内蒙皮层,所述第一组合和所述第二组合是不同的,所述内蒙皮层对应于所述转子叶片的内表面;
将所述外蒙皮层和所述内蒙皮层以堆叠构造布置在一起;以及
将所述外蒙皮层和所述内蒙皮层连结在一起以形成所述转子叶片的外蒙皮。
2.根据权利要求1所述的方法,其特征在于,所述方法还包括基于涂料增加、紫外线(UV)防护、热防护、腐蚀防护或防止结冰中的至少一个来定制所述第一组合,所述第一组合包括热塑性材料。
3.根据权利要求1所述的方法,其特征在于,所述第一组合和所述第二组合的一种或多种树脂中的至少一种包括非晶态热塑性材料。
4.根据权利要求1所述的方法,其特征在于,所述方法还包括基于兼容性、结合效率、焊接效率或结构性能中的至少一个来定制所述第二组合。
5.根据权利要求4所述的方法,其特征在于,所述第二组合的一种或多种树脂包括热塑性材料或热固性材料中的至少一种,且所述第二组合的纤维材料包括玻璃纤维、碳纤维、聚合物纤维、木纤维、竹纤维、陶瓷纤维、纳米纤维或金属纤维中的至少一种。
6.根据权利要求1所述的方法,其特征在于,所述方法还包括由热塑性材料形成所述外蒙皮层或所述内蒙皮层中的一个,以及由热固性材料形成所述外蒙皮层或所述内蒙皮层中的另一个,其中由所述热固性材料形成的所述蒙皮层包括能够挠曲以允许所述蒙皮层在连结期间真空顺应于模具的厚度。
7.根据权利要求1所述的方法,其特征在于,所述方法还包括在所述外蒙皮层或所述内蒙皮层中的至少一个中使一定量的热塑性材料偏置,以产生树脂富集区域和/或树脂缺乏区域。
8.根据权利要求1所述的方法,其特征在于,所述方法还包括在所述外蒙皮层与所述内蒙皮层之间放置至少一个结构层,其中所述至少一个结构层包括拉挤物、一个或多个金属层、一个或多个玻璃层、木、泡沫、结构泡沫或纤维材料中的至少一种。
9.根据权利要求1所述的方法,其特征在于,所述方法还包括经由带压制、一种或多种粘合剂、灌注、真空成型或热成型中的至少一种来将第一外蒙皮层和第二外蒙皮层连结在一起。
10.根据权利要求1所述的方法,其特征在于,所述方法还包括使一个或多个次级构件结合到所述外蒙皮层、所述内蒙皮层或布置在它们之间的至少一个结构层中,所述一个或多个次级构件包括一个或多个传感器、传感器线、传导元件或材料、自修复元件、加热元件、电磁屏蔽件、管道、一个或多个通道、焊接条或焊接网中的至少一种。
11.根据权利要求10所述的方法,其特征在于,使所述一个或多个次级构件结合到所述外蒙皮层、所述内蒙皮层或所述至少一个结构层中的至少一个中还包括3D打印所述一个或多个次级构件、手动放置所述一个或多个次级构件、经由机器人系统自动放置所述一个或多个次级构件,或灌注所述一个或多个次级构件中的至少一种。
12.根据权利要求11所述的方法,其特征在于,所述方法还包括经由光投影系统来对准所述一个或多个次级构件。
13.根据权利要求1所述的方法,其特征在于,所述方法还包括将至少一个结构构件打印和沉积到连结的外蒙皮层和/或内蒙皮层上。
14. 一种用于风力涡轮的转子叶片的转子叶片板,所述转子叶片板包括:
外蒙皮层,所述外蒙皮层由一种或多种树脂或纤维材料中的至少一种的第一组合来形成,所述外蒙皮层形成所述转子叶片板的外表面;以及
内蒙皮层,所述内蒙皮层与所述外蒙皮层相邻布置,所述内蒙皮层由一种或多种树脂或纤维材料中的至少一种的第二组合来形成,所述第一组合和所述第二组合是不同的,
所述外蒙皮层和所述内蒙皮层形成所述转子叶片板的翼型件形状的至少一部分。
15.根据权利要求14所述的转子叶片板,其特征在于,所述转子叶片板包括压力侧表面、吸力侧表面、后缘、前缘或其组合中的至少一个。
16.根据权利要求14所述的转子叶片板,其特征在于,一个的所述第一组合基于涂料增加、紫外线(UV)防护、热防护、腐蚀防护或防止结冰中的至少一个来定制,其中所述第一组合和所述第二组合的一种或多种树脂中的至少一种包括热塑性材料。
17.根据权利要求14所述的转子叶片板,其特征在于,所述第二组合基于兼容性、结合效率、焊接效率或结构性能中的至少一个来定制。
18.根据权利要求14所述的转子叶片板,其特征在于,所述转子叶片板还包括在所述外蒙皮层或所述内蒙皮层中的至少一个中的热塑性材料的树脂富集区域和/或树脂缺乏区域中的至少一个。
19.根据权利要求14所述的转子叶片板,其特征在于,所述转子叶片板还包括布置在所述外蒙皮层与所述内蒙皮层之间的至少一个结构层,所述至少一个结构层包括拉挤物、一个或多个金属层、一个或多个玻璃层或纤维材料中的至少一种。
20.根据权利要求19所述的转子叶片板,其特征在于,所述转子叶片板还包括结合到所述外蒙皮层、所述内蒙皮层或所述至少一个结构层中的一个或多个次级构件,所述一个或多个次级构件包括一个或多个传感器、传感器线、传导元件或材料、自修复元件、加热元件、电磁屏蔽件、管道、一个或多个通道、焊接条或焊接网中的至少一种。
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CA3082599A1 (en) | 2019-05-31 |
WO2019103831A3 (en) | 2019-08-08 |
US20190153995A1 (en) | 2019-05-23 |
EP3713737A4 (en) | 2021-09-01 |
BR112020009504A2 (pt) | 2020-11-03 |
EP3713737A2 (en) | 2020-09-30 |
WO2019103831A2 (en) | 2019-05-31 |
US11668275B2 (en) | 2023-06-06 |
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