CN112041154A - 用于碳部件的制造方法和工具 - Google Patents

用于碳部件的制造方法和工具 Download PDF

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CN112041154A
CN112041154A CN201980030290.5A CN201980030290A CN112041154A CN 112041154 A CN112041154 A CN 112041154A CN 201980030290 A CN201980030290 A CN 201980030290A CN 112041154 A CN112041154 A CN 112041154A
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carbon
manufacturing
protrusions
parts
pultrusion
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CN112041154B (zh
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D·S·佩德森
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Siemens Gamesa Renewable Energy AS
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
    • B29C70/523—Pultrusion, i.e. forming and compressing by continuously pulling through a die and impregnating the reinforcement in the die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4855—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by their physical properties, e.g. being electrically-conductive
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint 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
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/23—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations
    • B29C66/232—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General 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
    • B29C66/72—General 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
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
    • B29C70/525—Component parts, details or accessories; Auxiliary operations
    • B29C70/526—Pultrusion dies, e.g. dies with moving or rotating parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • B29C70/747—Applying material, e.g. foam, only in a limited number of places or in a pattern, e.g. to create a decorative effect
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • B29C70/882—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/065—Rotors characterised by their construction elements
    • F03D1/0675—Rotors characterised by their construction elements of the blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D80/00—Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
    • F03D80/30—Lightning protection
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B29C65/4865—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding containing additives
    • B29C65/4885—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding containing additives characterised by their composition being non-plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/524—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive by applying the adhesive from an outlet device in contact with, or almost in contact with, the surface of the part to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0003—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular electrical or magnetic properties, e.g. piezoelectric
    • B29K2995/0005—Conductive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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    • B29L2031/001—Profiled members, e.g. beams, sections
    • B29L2031/003—Profiled members, e.g. beams, sections having a profiled transverse cross-section
    • B29L2031/005—Profiled members, e.g. beams, sections having a profiled transverse cross-section for making window frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • Y—GENERAL 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

制造包括至少两个碳部件(50)的产品的方法包括以下步骤：‑制造第一碳部件(50)；‑制造至少第二碳部件(50)；‑在第一碳部件或第二碳部件(50)中的一个的表面(51)上提供包括碳树脂的多个突出部(52、53)；‑使第一碳部件和第二碳部件(50)连结在一起，使得多个突出部(52、53)插置在第一碳部件与第二碳部件(50)之间，用于提供物理和电气连接。

Description

用于碳部件的制造方法和工具
技术领域
本发明涉及用于改善碳部件的传导性的制造方法。本发明进一步涉及用于拉挤成型制造具有改善的传导性的碳部件的工具。
背景技术
碳部件通常用于各种工业领域中。例如，碳部件可用于制造叶片，用于风力涡轮机，以能够使其与仅使用玻璃纤维材料而制造的叶片相比更长并且更轻。此类碳部件通常可通过拉挤成型过程制造。
在类似风力涡轮机具有大尺寸的构造中，导电部件通常需要电气连接到避雷系统，包括风力涡轮机叶片的碳部件，因为碳是导电材料。
为了提供高效的避雷系统，重要的是，实现接触部件之间的良好传导性。这要求控制接触部件之间的接触表面。在存在有碳部件的情况下，控制接触部件之间的接触表面可导致问题，因为例如通过拉挤成型制造的此类部件的表面通常不规则。
用于改善碳部件之间的导电性的一个已知解决方案是打磨部件，并且在其之间插入碳纤维遮片（matte）。
另一已知解决方案是在多个位置上将碳部件螺栓连接在一起。
然而，这两个解决方案是耗时的，并且增加材料成本。
因此，仍然需要提供用于制造包括至少两个碳部件的产品的制造过程，其中，通过相对于现有技术减少制造时间和材料成本，以高效方式改善了碳部件之间的导电性。
发明内容
可通过根据所附独立权利要求的主题而满足此需要。由从属权利要求描述了本发明的有利实施例。
根据本发明的第一方面，提供了制造包括至少两个碳部件的产品的方法。方法包括以下步骤：
-制造第一碳部件，
-制造至少第二碳部件，
-在第一碳部件或第二碳部件中的一个的表面上提供包括碳树脂的多个突出部，
-使第一碳部件和第二碳部件连结在一起，使得多个突出部插置在第一碳部件与第二碳部件之间，用于提供物理和电气连接。
相对于现有技术，多个传导突出部允许以更少材料和成本改善两个碳部件之间的接触。进一步地，可控制突出部的分布，因此提供的进一步优点是，可在期望精度的情况下提供碳部件之间的物理和电气接触。
根据本发明的实施例，多个突出部可包括一个或多个点状物、一个或多个条带或点状物和条带的组合。
点状物和条带可被注入或沉积。
点状物和条带可以式样组织。
根据本发明的具体实施例，通过拉挤成型而制造将连结的第一碳部件和第二碳部件中的至少一个。在此类实施例中，在拉挤成型步骤期间，多个突出部被提供在第一碳部件或第二碳部件中的一个的表面上。特别地，在拉挤成型模具内部，多个突出部可被沉积在第一碳部件或第二碳部件中的一个的表面上。
根据本发明的第二方面，提供了拉挤成型模具。拉挤成型模具沿着拉挤成型方向在用于接收多个纤维的第一入口区段与用于递送多个树脂浸渍纤维的第二出口区段之间纵向延伸，其中，拉挤成型模具包括带部，所述带部包括多个突出部，所述多个突出部包括碳树脂，带部被设置成使得当多个纤维从入口区段到出口区段穿过拉挤成型模具时，多个突出部从带部转移到多个纤维。
根据本发明的实施例，带部围绕横向于拉挤成型方向的带部轴线环状地成形，环状带部能够围绕带部轴线旋转。
上文描述的拉挤成型模具在拉挤成型过程期间允许在稍后将连结在一起的碳部件上的突出部沉积的自动化。
本发明可有利地用于制造包括碳树脂突出部的碳部件，所述碳部件将集成在风力涡轮机叶片中。
必须注意的是，已参考不同主题而描述了本发明的实施例。特别地，已参考装置（拉挤成型模具）类型权利要求而描述了一些实施例，而已参考方法类型权利要求而描述了其它实施例。然而，本领域技术人员将从上文和以下描述得出的是，除非另有说明，否则除了属于一种类型的主题的特征的任何组合以外，涉及不同主题的特征之间（特别是方法类型权利要求的特征和设备类型权利要求的特征之间）的任何组合也被认为与此文档一起公开。
本发明的上文限定的方面和其它方面根据下文将描述的实施例的示例而显而易见，并且参考实施例的示例解释。下文将参考实施例的示例而更详细地描述本发明，但是本发明不限于其。
附图说明
图1显示了利用本发明的方法而获得的第一产品的示意性轴测视图。
图2显示了利用本发明的方法而获得的第二产品的示意性轴测视图。
图3显示了根据本发明的拉挤成型模具的示意性轴测视图。
图4显示了包括转子叶片的风力涡轮机的示意性截面，所述转子叶片包括根据本发明制造的产品。
具体实施方式
附图中的图示是示意性的。应注意的是，在不同附图中，类似或相同的元件被提供有相同的附图标记。
图1显示了碳部件50，在所述碳部件50上，包括碳树脂的多个突出部52被沉积或注入在碳部件50的表面51之上。
特别地，碳部件50由包括多个碳纤维和树脂的复合材料制成。突出部52呈点状物的形式，并且根据包括列和行的矩形式样分布。
根据本发明的其它实施例（未显示），多个点状物52可根据任何其它式样分布。
碳部件50可连结到另一碳部件（未显示），使得多个突出部插置在第一碳部件与第二碳部件之间，用于提供物理和电气连接。突出部52可被提供在将连结的两个碳部件上。
图2显示了碳部件50，在所述碳部件50上，包括碳树脂的多个突出部53被沉积或注入在表面51之上。
不同于图1的实施例，突出部53呈平行条带的形式。在碳部件50是包括多个碳纤维的复合材料的情况下，条带50可相对于条带50正交或平行或倾斜。
图3显示了拉挤成型模具20，其可用于自动沉积图1的实施例的多个突出部点状物52。
拉挤成型模具20沿着拉挤成型方向X在用于接收多个纤维110的第一入口区段21与用于递送多个树脂浸渍纤维的第二出口区段22之间纵向延伸。
拉挤成型模具20包括带部25，所述带部25包括多个突出部52。
带部25围绕横向于拉挤成型方向X的带部轴线Z环状地成形，并且能够围绕带部轴线Z旋转。
根据本发明的其它实施例（未显示），带部是开放的，并且在两个带部端部之间延伸。在两个实施例中，带部的至少部分在入口区段21与出口区段22之间平移。
带部25沿着拉挤成型模具20的内侧设置，使得当多个纤维110从入口区段21到出口区段22穿过拉挤成型模具20时，多个突出部52从带部25转移到多个纤维110。根据本发明的其它实施例（未显示），拉挤成型模具20包括将转移到多个纤维110的多个条带突出部53。
图4显示了根据本发明的风力涡轮机1。风力涡轮机1包括塔架2，所述塔架2被安装在未描绘的基底上。机舱3布置在塔架2的顶部上。
风力涡轮机1还包括风力转子5，所述风力转子5具有两个、三个或更多个叶片4（在图1的透视图中，仅两个叶片4可见）。风力转子5可围绕旋转轴线Y旋转。叶片4相对于旋转轴线Y径向延伸。
风力转子5借助于可旋转主轴9与发电机30旋转地联接。
根据本发明的其它可能实施例（未表示在所附附图中），风力转子5直接与发电机30旋转地联接（直驱发电机配置）。
提供了示意性地描绘的轴承组件8，以便使转子5保持就位。可旋转主轴9沿着旋转轴线Y延伸。
叶片4包括通过本发明获得的一个或多个碳部件50。此类碳部件50连结到叶片的其它部分（其也可根据本发明获得），以便改善整个叶片的导电性。这改善了叶片4的避雷系统的性能。

Claims (12)

1.制造包括至少两个碳部件(50)的产品的方法，所述方法包括以下步骤：
-制造第一碳部件(50)，
-制造至少第二碳部件(50)，
-在所述第一碳部件或第二碳部件(50)中的一个的表面(51)上提供包括碳树脂的多个突出部(52、53)，
-使所述第一碳部件和所述第二碳部件(50)连结在一起，使得所述多个突出部(52、53)插置在所述第一碳部件与所述第二碳部件(50)之间，用于提供物理和电气连接。
2.根据权利要求1所述的制造方法，其中，所述多个突出部(52、53)包括至少一个点状物(52)。
3.根据权利要求1或2所述的制造方法，其中，所述多个突出部(52、53)包括至少一个条带(53)。
4.根据前述权利要求1至3中任一项所述的制造方法，其中，多个突出部(52、53)被注入在所述第一碳部件或第二碳部件(50)中的一个的表面(51)上。
5.根据前述权利要求1至3中任一项所述的制造方法，其中，多个突出部(52、53)被沉积在所述第一碳部件或第二碳部件(50)中的一个的表面(51)上。
6.根据前述权利要求中任一项所述的制造方法，其中，所述多个突出部(52、53)以式样组织。
7.根据前述权利要求中任一项所述的制造方法，其中，通过拉挤成型而制造所述第一碳部件和第二碳部件(50)中的至少一个。
8.根据权利要求7所述的制造方法，其中，在拉挤成型步骤期间，所述多个突出部(52、53)被提供在所述第一碳部件或第二碳部件(50)中的一个的表面(51)上。
9.根据权利要求8所述的制造方法，其中，在拉挤成型模具内部，所述多个突出部(52、53)被沉积在所述第一碳部件或第二碳部件(50)中的一个的表面(51)上。
10.根据前述权利要求中任一项所述的制造方法，其中，所述第一碳部件或第二碳部件(50)中的一个是风力涡轮机叶片(4)的部分。
11.拉挤成型模具(20)，沿着拉挤成型方向(X)在用于接收多个纤维(110)的第一入口区段(21)与用于递送多个树脂浸渍纤维的第二出口区段(22)之间纵向延伸，其中，所述拉挤成型模具(20)包括带部(25)，所述带部(25)包括多个突出部(52、53)，所述多个突出部(52、53)包括碳树脂，所述带部(25)被设置成使得当所述多个纤维(110)从所述入口区段(21)到所述出口区段(22)穿过所述拉挤成型模具(20)时，所述多个突出部(52、53)从所述带部(25)转移到所述多个纤维(110)。
12.根据权利要求11所述的拉挤成型模具(20)，其中，所述带部(25)围绕横向于所述拉挤成型方向(X)的带部轴线(Z)环状地成形，环状带部(25)能够围绕所述带部轴线(Z)旋转。
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