CN113115589A - Method and equipment for manufacturing graphene modified fiber reinforced material - Google Patents

Method and equipment for manufacturing graphene modified fiber reinforced material Download PDF

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Publication number
CN113115589A
CN113115589A CN201980042146.3A CN201980042146A CN113115589A CN 113115589 A CN113115589 A CN 113115589A CN 201980042146 A CN201980042146 A CN 201980042146A CN 113115589 A CN113115589 A CN 113115589A
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graphene
fiber bundle
fiber
potting
resins
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孙建旭
梁嫄
马豪
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Envision Energy Co Ltd
Envision Energy Ltd
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Envision Energy Co Ltd
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/04—Carbon
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B15/00—Removing liquids, gases or vapours from textile materials in association with treatment of the materials by liquids, gases or vapours
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    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B23/00—Component parts, details, or accessories of apparatus or machines, specially adapted for the treating of textile materials, not restricted to a particular kind of apparatus, provided for in groups D06B1/00 - D06B21/00
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    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B23/00—Component parts, details, or accessories of apparatus or machines, specially adapted for the treating of textile materials, not restricted to a particular kind of apparatus, provided for in groups D06B1/00 - D06B21/00
    • D06B23/20—Arrangements of apparatus for treating processing-liquids, -gases or -vapours, e.g. purification, filtration or distillation
    • D06B23/22—Arrangements of apparatus for treating processing-liquids, -gases or -vapours, e.g. purification, filtration or distillation for heating
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    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06B3/00—Passing of textile materials through liquids, gases or vapours to effect treatment, e.g. washing, dyeing, bleaching, sizing, impregnating
    • D06B3/04—Passing of textile materials through liquids, gases or vapours to effect treatment, e.g. washing, dyeing, bleaching, sizing, impregnating of yarns, threads or filaments
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/73—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof
    • D06M11/74—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof with carbon or graphite; with carbides; with graphitic acids or their salts
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    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
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    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/227—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of hydrocarbons, or reaction products thereof, e.g. afterhalogenated or sulfochlorinated
    • D06M15/233—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of hydrocarbons, or reaction products thereof, e.g. afterhalogenated or sulfochlorinated aromatic, e.g. styrene
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    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/244—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of halogenated hydrocarbons
    • D06M15/248—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of halogenated hydrocarbons containing chlorine
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    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/39—Aldehyde resins; Ketone resins; Polyacetals
    • D06M15/41—Phenol-aldehyde or phenol-ketone resins
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    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/507—Polyesters
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    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
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    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/59—Polyamides; Polyimides
    • 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
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
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    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction
    • 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

The invention relates to a method for producing a graphene-modified fiber reinforcement, comprising the following steps: providing a fiber bundle; drawing the fiber bundle; adding graphene to a potting tank so that the graphene forms a potting material with a matrix in the potting tank; infiltrating the perfusion material onto the fiber bundle in a traction state in a perfusion groove; and extruding the fiber bundle coated with the potting material to form the graphene modified fiber reinforcement material. The invention also relates to equipment for manufacturing the graphene modified fiber reinforced material. The method can ensure the concentration and uniform distribution of the introduced graphene, thereby obviously improving the compressive strength of the fiber bundle, further obviously improving the strength of the material and the main bearing part of the blade and reducing the sensitivity of the strength of the material to the manufacturing process; in addition, due to the more uniformly distributed graphene, the conductivity of the material is remarkably improved, so that the lightning protection effect of the blade is improved.

Description

Method and equipment for manufacturing graphene modified fiber reinforced material Technical Field
The invention relates to the field of wind driven generators in general, and particularly relates to a method for manufacturing a graphene modified fiber reinforced material. In addition, the invention also relates to equipment for manufacturing the graphene modified fiber reinforced material.
Background
In recent years, with the increasing environmental importance of various countries, the field of clean energy has been rapidly developing. The clean energy is a novel energy, and has the advantages of wide distribution, reproducibility, small environmental pollution and the like compared with the traditional fossil fuel. Wind power generators are increasingly used as representatives of clean energy.
The blades of the wind driven generator are important components for capturing wind energy, wherein the blades mounted on the hub of the wind driven generator are driven by the wind energy to rotate so as to generate lift force, and the lift force is further converted into torque through a transmission chain in the engine room to drive the generator to generate electricity. In the same case, the larger the impeller formed by the blades, the more wind energy that can be captured, and therefore the longer the blades of the wind turbine, the higher the flapping stiffness of the blades, and the higher the deformation of the blades, so that the more efficient method is needed to increase the flapping stiffness of the blades to avoid the risk of tower-sweeping. Most blades today are constructed from two shells, which are divided into a pressure side shell and a suction side shell. The shell typically has a sandwich panel of glass fiber reinforced plastic and core material and a primary load-bearing component, a spar, wherein the spar contributes about 90% of the overall flapping stiffness.
To increase spar flapping stiffness, carbon fiber composite materials have been introduced into spars. Compared with carbon fiber prepreg and carbon fiber fabric infusion, the carbon fiber pultrusion process is increasingly applied to the blade industry due to excellent cost performance, stable process and quality control. Since the compressive strength of carbon fiber composites is much lower than the tensile strength, increasing the compressive strength will facilitate more efficient use of the material. However, the strength of the girder using the carbon fiber is currently sensitive to the manufacturing process, i.e., the girder strength fluctuates in a large range due to the difference or tolerance of the manufacturing process. In view of the trend of the blades to be increasingly longer, the strength of the main beam still needs to be further improved.
Disclosure of Invention
Starting from the prior art, the invention provides a method and equipment for manufacturing a graphene modified fiber reinforced material (or simply referred to as "material"), by which graphene can be conveniently introduced into the material and the introduced graphene has a required concentration and is more uniformly distributed among fiber bundles or fiber filaments, so that the compressive strength of the fiber reinforced composite material is remarkably improved, the strength of a main bearing part (such as a main beam and the like) of a blade is remarkably improved, and the sensitivity of the material strength to a manufacturing process is reduced; in addition, due to the more uniformly distributed graphene, the conductivity of the material is remarkably improved, so that the lightning protection effect of the blade is improved.
In a first aspect of the present invention, this task is solved by a method for manufacturing a graphene modified fiber reinforcement material, comprising the steps of:
providing a fiber bundle;
drawing the fiber bundle;
adding graphene to a potting tank so that the graphene forms a potting material with a matrix in the potting tank;
soaking the fiber bundle in a traction state into a perfusion material in a glue pouring groove; and
and extruding the fiber bundles soaked with the perfusion material to form the graphene modified fiber reinforced material.
It should be noted here that in the present invention, the term "fiber bundle" covers a bunch of a plurality of individual fibers. And the fiber bundle may comprise one or more fibers.
In one embodiment of the invention, it is provided that the graphene is a single-layer graphene or a multi-layer graphene. In addition, graphene may also exist in other forms, such as composites comprising graphene, graphene powders, graphene microparticles, and the like.
In a preferred embodiment of the invention, it is provided that the method further comprises the following steps:
stirring the pouring material in a glue pouring groove.
By the preferred scheme, the uniformity of the graphene in the matrix can be further improved, so that the compression strength of the fiber, such as the carbon fiber, is further improved.
In a further preferred embodiment of the invention, it is provided that the volume of the potting compound groove is less than or equal to 100 liters, preferably less than or equal to 50 liters. Through setting up the less encapsulating groove of capacity, can improve the distribution degree of consistency of graphite alkene to further improve the fibre, like the compressive strength of carbon fiber.
In one embodiment of the invention, it is provided that the fiber bundle comprises one or more of the following: carbon fibers, glass fibers, aramid fibers, boron fibers, basalt fibers, and ultra-high modulus polyethylene fibers. Other fiber bundles may be used as desired in other embodiments under the teachings of the present invention.
In a further embodiment of the invention, it is provided that the matrix comprises one or more of the following: thermosetting epoxy resins, vinyl resins, unsaturated polyester resins, phenolic resins, and thermoplastic resins. Other substrates may be used as desired in other embodiments, provided that the substrate is capable of being applied to a fiber bundle to form a desired material, under the teachings of the present invention. In a preferred embodiment, the matrix is a resin.
In a further embodiment of the invention, it is provided that the thermoplastic resin comprises one or more of the following: polypropylene resins, polyethylene resins, polyvinyl chloride resins, polystyrene resins, polyacrylonitrile-butadiene-styrene resins, polyamide resins, polyether ether ketone resins, and polyphenylene sulfide resins. Other resins may be employed as the matrix in other embodiments as desired under the teachings of the present invention.
In a preferred embodiment of the invention, it is provided that the graphene is a nanomaterial made of graphene. The nanomaterial may have a desired shape, such as a sphere, powder, flake, etc. By using a nanomaterial made of graphene having a specific shape, materials having different physical properties, such as different compressive strengths, can be manufactured.
In a second aspect of the present invention, the aforementioned task is solved by an apparatus for manufacturing graphene modified fiber reinforced material, comprising:
a creel having a spool for winding a fiber bundle, wherein the spool is configured to rotate to transport the fiber bundle while the fiber bundle is being pulled;
a pulling device configured to directly or indirectly pull the fiber bundle to bring the fiber bundle into a pulled state;
an injection molding box having a potting tank for containing a potting material and a first adding device for adding graphene, wherein the injection molding box is configured to allow a fiber bundle in a pulled state to pass through the potting tank such that the potting material is applied to the fiber bundle, wherein the potting material comprises a matrix and graphene; and
a forming device configured to extrude the fiber bundle coated with the potting material to form the graphene modified fiber reinforcement material.
In a preferred embodiment of the invention, it is provided that the injection-molded case further comprises a second filling device for filling the matrix. With this preferred solution, the matrix can be automatically added dynamically to the injection molding box, thus ensuring sufficient potting material, for example the amount of matrix remaining in the injection molding box can be detected by a level detection device, automatically added below a threshold value, or the matrix can be added in real time depending on the matrix consumption rate. The matrix and graphene can be fully mixed by arranging a plurality of matrix injection directions to form vortex in the addition process.
In one embodiment of the invention, it is provided that the device further comprises:
a heater configured to heat the formed graphene modified fiber reinforcement material; and/or
A curing chamber configured to cure the heated graphene modified fiber reinforcement material.
By means of this embodiment, heating and curing of the material can be achieved, so that a complete automation of the processing is achieved. Furthermore, a cutting device may be provided to cut the material into a desired shape.
In a preferred embodiment of the invention, it is provided that the device further comprises a fiber strand shaping rack which is arranged between the creel and the injection molding box for adjusting the relative position between the fiber strands. By using a shaping frame, the adjustment of the relative position between the fiber bundles can be achieved. For example, the fiber bundles may be evenly spaced apart so that substantially the same resin layer thickness can be filled between the fiber bundles, thereby filling substantially the same graphene between them, thereby improving the properties of the material, such as compressive strength and electrical conductivity.
In a further embodiment of the invention, it is provided that the volume of the potting compound channel is equal to or less than 100 liters, preferably equal to or less than 50 liters. Through setting up the less encapsulating groove of capacity, can improve the distribution degree of consistency of graphite alkene to further improve the fibre, like the compressive strength of carbon fiber.
In a further preferred embodiment of the invention, it is provided that the injection molding box further has a stirring device, which is configured to distribute the graphene uniformly in the matrix. By the preferred scheme, the uniformity of the graphene in the matrix can be further improved, so that the compression strength of the fiber, such as the carbon fiber, is further improved.
Furthermore, the invention relates to a graphene-modified fiber reinforcement material, which is manufactured using the method according to the invention.
In addition, the invention also relates to a main beam for the blade of the wind driven generator, which is provided with the graphene modified fiber reinforced material.
The invention has at least the following beneficial effects: (1) the graphene is added between the fiber bundles, particularly carbon fiber bundles, so that the interface performance of fibers and resin can be remarkably improved, the compression strength of the formed composite material is improved, the conductivity of the material is remarkably improved, and the lightning protection capability of the blade is improved; (2) by dynamically adding graphene directly to the potting bath, uniform distribution of graphene between fiber bundles can be significantly promoted, thereby ensuring uniform and consistent compressive strength and conductivity, based on the following insights of the present inventors: the inventor finds that an important reason that the strength of the main beam material is sensitive to the manufacturing process is that the existing stirring process is difficult to uniformly distribute the reinforcing particles (such as graphene used in the invention) in the resin, and the uneven distribution of the reinforcing particles in the resin can cause the strength, especially the compressive strength, of the main beam material to be significantly changed (for example, the strength at the position with low concentration of the reinforcing particles is also low), so that the strength of the main beam material is very dependent on the uniform stirring process of the reinforcing particles; meanwhile, the present inventors have unexpectedly found that, compared to pre-mixing graphene and resin in a large container (e.g., 2 ton capacity), dynamically adding graphene to a small-capacity glue-pouring bath (the capacity of which is generally less than 100L, preferably less than or equal to 50L) can ensure the concentration of the introduced graphene in the resin and greatly improve the distribution uniformity of the graphene in the resin and simplify the stirring process at the same time, because when the graphene is dynamically added to the small-capacity glue-pouring bath in real time, a more uniform distribution of the graphene can be achieved by adding the initial flow rate of the graphene or slightly stirring, or the uniformly-fed graphene can be uniformly coated on the fiber bundle without stirring, which can ensure the desired concentration of the graphene and improve the stirring uniformity compared to fully stirring in the large container in advance, and the stirring process is simplified, so that the uniform distribution of graphene among fiber bundles can be improved, the compressive strength of the fiber bundles is improved, the sensitivity of the material to the process is reduced, and the conductivity of the material is unexpectedly improved.
Drawings
The invention is further elucidated with reference to the drawings in conjunction with the detailed description.
Fig. 1 shows a schematic view of an apparatus for manufacturing graphene modified fibre reinforced material according to the present invention;
figure 2 shows a cross-sectional view of a graphene modified fibre reinforcement material according to the present invention;
FIG. 3 illustrates a cross-sectional view of a spar in accordance with the present invention;
FIG. 4 shows a cross-sectional view of a fan blade according to the present disclosure; and
fig. 5 shows a flow of a method for manufacturing graphene modified fibre reinforced material according to the present invention.
Detailed Description
It should be noted that the components in the figures may be exaggerated and not necessarily to scale for illustrative purposes. In the figures, identical or functionally identical components are provided with the same reference symbols.
In the present invention, "disposed on …", "disposed over …" and "disposed over …" do not exclude the presence of an intermediate therebetween, unless otherwise specified. Further, "disposed on or above …" merely indicates the relative positional relationship between two components, and may also be converted to "disposed below or below …" and vice versa in certain cases, such as after reversing the product direction.
In the present invention, the embodiments are only intended to illustrate the aspects of the present invention, and should not be construed as limiting.
In the present invention, the terms "a" and "an" do not exclude the presence of a plurality of elements, unless otherwise specified.
It is further noted herein that in embodiments of the present invention, only a portion of the components or assemblies may be shown for clarity and simplicity, but those of ordinary skill in the art will appreciate that, given the teachings of the present invention, required components or assemblies may be added as needed in a particular scenario.
It is also noted herein that, within the scope of the present invention, the terms "same", "equal", and the like do not mean that the two values are absolutely equal, but allow some reasonable error, that is, the terms also encompass "substantially the same", "substantially equal". By analogy, in the present invention, the terms "perpendicular", "parallel" and the like in the directions of the tables also cover the meanings of "substantially perpendicular", "substantially parallel".
The numbering of the steps of the methods of the present invention does not limit the order of execution of the steps of the methods. Unless specifically stated, the method steps may be performed in a different order.
The present invention is based on the following insight of the inventors: one important reason why the strength, especially the compressive strength, of the existing girder materials is sensitive to the manufacturing process is that during the manufacturing process of the existing girder materials, the potting material is stirred in the vat, which results in a distribution of the reinforcing particles in the resin that is very much dependent on the stirring process, and that is not necessarily homogeneously mixed even if mixed for a long time, thus resulting in a large variation in the strength of the manufactured material, since the amount of reinforcing particles added in the vat is much smaller compared to the amount of resin; the inventors discovered through research that by dynamically adding graphene directly to the potting bath, uniform distribution of graphene between the fiber bundles can be significantly promoted, thereby further improving compressive strength and unexpectedly improving material conductivity, based on the inventors' insight; this is because, compared with pre-mixing graphene and resin in a large container (e.g. 2 ton capacity), dynamically adding graphene directly into a small-capacity potting tank (the capacity of which is generally less than 100L, preferably less than or equal to 50L) will ensure the concentration of graphene in resin and greatly improve the distribution uniformity of graphene in resin and simplify the stirring process, because when graphene is dynamically added into a small-capacity potting tank in real time, the graphene can be distributed more uniformly by adding the initial flow rate of graphene or slightly stirring, or the graphene which is input at a constant speed can be uniformly coated on the fiber bundle without stirring, which can ensure the required concentration of graphene and improve the stirring uniformity compared with pre-stirring in a large container, and also simplifies the stirring process, thereby improving the uniform distribution of graphene among the fiber bundles, thereby improving the compressive strength of the fiber bundle and the conductive capability of the material.
The invention is further illustrated below with reference to specific embodiments and the accompanying drawings.
Fig. 1 shows a schematic view of an apparatus 100 for manufacturing graphene modified fibre reinforced material according to the present invention.
As shown in fig. 1, an apparatus 100 for manufacturing graphene modified fiber reinforced material (or simply "material") according to the present invention includes the following components (some of which are optional):
a creel 101 having a spool 102 for winding a fiber bundle. In this embodiment, creel 101 has 12 spools 102, and in other embodiments, other numbers of spools may be provided. The creel 101 may be placed vertically or horizontally and the reel 102 is arranged with its axis of rotation perpendicular to the plane in which the creel 101 lies. The reel 102 is configured to rotate to convey the fiber bundles 103a, 103b while the fiber bundles 103a, 103b are pulled. In this embodiment, the spool 102 carries two different fibre bundles 103a, 103b, in other embodiments more or one fibre bundle may be provided. The different fiber bundles 103a, 103b may differ, for example, in their composition, thickness, or other parameters. In a preferred embodiment, the fiber bundles 103a, 103b comprise or are carbon fiber bundles, whereby the tensile strength and the electrical conductivity of the material may be increased. Improved electrical conductivity facilitates lightning protection of the blade, since when lightning strikes the blade, current may be grounded through the electrically conductive material on the blade, thereby avoiding the creation of electrical arcs or sparks.
A pulling device (not shown) configured to directly or indirectly pull the fiber bundles 103a, 103b to bring the fiber bundles into a pulled state. For example, the pulling device may pull the fiber bundles 103a, 103b at the finished material 111 or other location. Here, the pulling force may be so great that the fiber bundles 103a, 103b can be straightened and the reel 102 rotated at a desired speed in order to transport the fiber bundles 103a, 103b at a desired speed. The pulling device can be, for example, a stepping motor, which pulls and advances the fiber bundles 103a, 103b by means of a belt.
An optional fiber bundle shaping rack 104 arranged between the creel and the injection molding box for adjusting the relative position between the fiber bundles. By using the shaping frame 104, an adjustment of the relative position between the fiber bundles 103a, 103b or between the individual fibers of the fiber bundles 103a, 103b can be achieved. For example, the fiber bundles may be evenly spaced apart so that substantially the same resin layer thickness can be filled between the fiber bundles, thereby filling substantially the same graphene between them, thereby improving the properties of the material, such as compressive strength and electrical conductivity.
An injection molding box 105 having a potting tank (not shown) for containing a potting material and a first adding means for adding graphene, wherein the injection molding box is configured to allow the fiber bundle in a pulled state to pass through the potting tank such that the potting material is applied onto the fiber bundles 103a, 103b, wherein the potting material comprises a resin 106 and graphene 107. Graphene 107 may be single-layer graphene or multi-layer graphene. The graphene 107 may also exist in other forms, such as composites comprising graphene, graphene powders, graphene microparticles, graphene nanomaterials, graphene solutions, and the like. Here, the graphene 107 is dynamically added to the injection molding box 105 by the first adding means, and the resin 106 is dynamically added to the injection molding box 105 by the second adding means. The first and second adding means are for example delivery pipes with electric pumps. By means of the first and second adding means, the numbers 106 and the graphene 107 can be automatically added to the injection molding box 105 dynamically, thereby ensuring sufficient potting material. The amount of resin remaining in the injection molding box 105 may be detected by a liquid level detection device, the resin may be automatically added when below a threshold value, or the resin may be added in real time according to the resin consumption rate, for example. In the adding process, a plurality of resin conveying pipelines with different input directions can be arranged to enable the output resin to form a vortex, so that the resin and the graphene can be fully mixed. In this embodiment, the fiber bundles 103a, 103b are passed through the potting channels in the injection molding box 105 at a uniform velocity so that each fiber bundle can be adequately coated with a potting material, i.e., a mixture of resin and graphene. For example, the graphene 107 may be added at a uniform rate (i.e., the same amount of graphene 107 is added per unit time, and the adding rate may be determined according to the required concentration of the graphene 107 in the resin 106), so that the graphene 107 input at a uniform rate may be uniformly coated on the fiber bundle. In this case, the addition position of the graphene is preferably close to the position where the fiber bundle contacts the potting material, so that the added graphene can be instantly coated on the fiber bundle. The volume of the potting compound channel is equal to or less than 100 liters, preferably equal to or less than 50 liters, for example 40 liters, 30 liters, etc. Through setting up the less encapsulating groove of capacity and the graphite alkene of dynamic addition, can improve the distribution degree of consistency of graphite alkene to further improve the fibre, like the compressive strength of carbon fiber. This is because, compared with pre-mixing graphene and resin in a large container (e.g. 2 ton capacity), dynamically adding graphene directly into a small-capacity potting tank (the capacity of which is generally less than 100L, preferably less than or equal to 50L) will ensure the concentration of graphene in resin and greatly improve the distribution uniformity of graphene in resin and simplify the stirring process, because when graphene is dynamically added into a small-capacity potting tank in real time, the graphene can be distributed more uniformly by adding the initial flow rate of graphene or slightly stirring, or the graphene which is input at a constant speed can be uniformly coated on the fiber bundle without stirring, which can ensure the required concentration of graphene and improve the stirring uniformity compared with pre-stirring in a large container, and also simplifies the stirring process, thereby improving the uniform distribution of graphene among the fiber bundles, thereby improving the compressive strength of the fiber bundle and the conductive capability of the material.
A forming device 109 configured to press the fiber bundles 103a, 103b coated with the potting material to form the graphene modified fiber reinforcement material 111. The molding device 109 is, for example, a mold.
An optional heater 109 configured to heat the formed graphene modified fibre reinforced material 111. By the pressing, the resin 106 and the graphene 107 are filled more deeply between the fiber bundles 103a, 103 b.
An optional curing chamber (not shown) configured to cure the heated graphene modified fibre reinforced material. The curing chamber is optional as curing can also be performed outside the apparatus.
Fig. 2 shows a cross-sectional view of a graphene modified fibrous reinforcement 111 according to the present invention.
As shown in fig. 2, there are two types of fiber bundles 103a, 103b distributed in the material 111, in other embodiments, fewer or more types of fiber bundles are also contemplated. A mixture of graphene 107 and resin 106 is filled between the fiber bundles 103a, 103b, wherein the graphene 107 is uniformly distributed in the mixture. Thus, the material 111 manufactured according to the method and apparatus of the present invention has better strength, particularly compressive strength, and better electrical conductivity, thereby providing better material quality and lightning protection capabilities.
Fig. 3 shows a cross-sectional view of a main beam 300 according to the present invention.
As shown in fig. 3, the girder 300 comprises upper and lower layers of material 111 according to the invention, and a plurality of layers of compression plates 301 are arranged between the two layers of material 111. Here, the compression plate 301 is laid two layers in the chord direction and four layers in the thickness direction. In other embodiments, other layers of the pressing plates 301 may be laid in the two directions, and other layers of the material 111 may be arranged. As can be seen from fig. 3, by using the material 111 according to the invention, the strength, in particular the compressive strength, of the girder 300 can be increased. In addition, due to the more evenly distributed graphene between the fiber bundles, the material 111 has higher conductivity, so that the main beam 300 has higher conductivity, thereby improving the lightning protection capability of the blade.
Fig. 4 shows a cross-sectional view of a fan blade 400 according to the invention.
As shown in FIG. 4, the blade 400 includes a leading edge 401 and a trailing edge 405, as well as a pressure side (PS side) 402 and a suction side (SS side) 404. The blade 400 also includes the spar 300 as its primary load-bearing structure, and also includes a web 403 for supporting the spar 300. Here, by using the girder 300 having the material 111, the strength and the electrical conductivity of the girder 300 can be significantly improved, thereby improving the strength and the electrical conductivity of the entire blade 400.
Fig. 5 shows a flow 500 of a method for manufacturing graphene modified fiber reinforced material according to the present invention.
A fiber bundle is provided at step 502. The fiber bundle may comprise one or more fiber bundles.
At step 504, the fiber bundle is pulled.
At step 506, graphene is added to the potting bath such that the graphene forms a potting material with the matrix in the potting bath. The addition is on-site and dynamic, so that the uniformity of the graphene in the resin can be improved, and the addition and stirring processes are simplified. For example, the graphene 107 may be added at a uniform rate (i.e., the same amount of graphene 107 is added per unit time, and the adding rate may be determined according to the desired concentration of the graphene 107 in the resin 106), so that the desired concentration of graphene is ensured and the graphene 107 input at a uniform rate may be uniformly coated on the fiber bundle. In this case, the addition position of the graphene is preferably close to the position where the fiber bundle contacts the potting material, so that the added graphene can be instantly coated on the fiber bundle.
At step 508, the fiber bundle in a pulled state is infiltrated into a potting material in a potting bath. For example, the fiber bundle may be pulled through the potting bath such that the potting material in the potting bath is automatically and uniformly applied to the fiber bundle, and in particular to each fiber in the fiber bundle.
At step 510, the fiber bundles infiltrated with the potting material are pressed to form the graphene modified fiber reinforced material.
The invention has at least the following beneficial effects: (1) the graphene is added between the fiber bundles, particularly carbon fiber bundles, so that the interface performance of fibers and resin can be remarkably improved, the compression strength of the formed composite material is improved, the conductivity of the material is remarkably improved, and the lightning protection capability of the blade is improved; (2) by dynamically adding graphene directly to the potting bath, uniform distribution of graphene between fiber bundles can be significantly promoted, thereby ensuring uniform and consistent compressive strength and conductivity, based on the following insights of the present inventors: the inventor finds that an important reason that the strength of the main beam material is sensitive to the manufacturing process is that the existing stirring process is difficult to uniformly distribute the reinforcing particles (such as graphene used in the invention) in the resin, and the uneven distribution of the reinforcing particles in the resin can cause the strength, especially the compressive strength, of the main beam material to be significantly changed (for example, the strength at the position with low concentration of the reinforcing particles is also low), so that the strength of the main beam material is very dependent on the uniform stirring process of the reinforcing particles; meanwhile, the present inventors have unexpectedly found that, compared to pre-mixing graphene and resin in a large container (e.g., 2 ton capacity), dynamically adding graphene to a small-capacity potting tank (the capacity of which is generally less than 100L, preferably less than or equal to 50L) ensures the concentration of graphene in resin and greatly improves the distribution uniformity of graphene in resin and simplifies the stirring process, because when graphene is dynamically added to a small-capacity potting tank in real time, a more uniform distribution of graphene can be achieved by adding the initial flow rate of graphene or slightly stirring, or graphene input at a uniform speed can be uniformly coated on a fiber bundle without stirring, which can ensure the desired concentration of graphene and improve the stirring uniformity compared to fully stirring in a large container in advance, and the stirring process is simplified, so that the uniform distribution of graphene among fiber bundles can be improved, the compressive strength of the fiber bundles is improved, the sensitivity of the material to the process is reduced, and the conductivity of the material is unexpectedly improved.
Although some embodiments of the present invention have been described herein, those skilled in the art will appreciate that they have been presented by way of example only. Numerous variations, substitutions and modifications will occur to those skilled in the art in light of the teachings of the present invention without departing from the scope thereof. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.

Claims (16)

  1. A method for manufacturing a graphene modified fibrous reinforcement material, comprising the steps of:
    providing a fiber bundle;
    drawing the fiber bundle;
    adding graphene to a potting tank so that the graphene forms a potting material with a matrix in the potting tank;
    soaking the fiber bundle in a traction state into a perfusion material in a glue pouring groove; and
    and extruding the fiber bundles soaked with the perfusion material to form the graphene modified fiber reinforced material.
  2. The method of claim 1, wherein the graphene is single-layer graphene or multi-layer graphene.
  3. The method of claim 1, further comprising the steps of:
    stirring the pouring material in a glue pouring groove.
  4. Method according to claim 1, wherein the volume of the glue bath is equal to or less than 100 litres, preferably equal to or less than 50 litres.
  5. The method of claim 1, wherein the fiber bundle comprises one or more of: carbon fibers, glass fibers, aramid fibers, boron fibers, basalt fibers, and ultra-high modulus polyethylene fibers.
  6. The method of claim 1, wherein the substrate comprises one or more of: thermosetting epoxy resins, vinyl resins, unsaturated polyester resins, phenolic resins, and thermoplastic resins.
  7. The method of claim 6, wherein the thermoplastic resin comprises one or more of: polypropylene resins, polyethylene resins, polyvinyl chloride resins, polystyrene resins, polyacrylonitrile-butadiene-styrene resins, polyamide resins, polyether ether ketone resins, and polyphenylene sulfide resins.
  8. The method of claim 1, wherein the graphene is a nanomaterial made from graphene.
  9. An apparatus for manufacturing graphene modified fiber reinforced material, comprising:
    a creel having a spool for winding a fiber bundle, wherein the spool is configured to rotate to transport the fiber bundle while the fiber bundle is being pulled;
    a pulling device configured to directly or indirectly pull the fiber bundle to bring the fiber bundle into a pulled state;
    an injection molding box having a potting tank for containing a potting material and a first adding device for adding graphene, wherein the injection molding box is configured to allow a fiber bundle in a pulled state to pass through the potting tank so that the potting material infiltrates onto the fiber bundle, wherein the potting material comprises a matrix and graphene; and
    a forming device configured to extrude the fiber bundle coated with the potting material to form the graphene modified fiber reinforcement material.
  10. The apparatus of claim 9, wherein the injection molding cartridge further comprises a second adding device for adding the matrix.
  11. The apparatus of claim 9, further comprising:
    a heater configured to heat the formed graphene modified fiber reinforcement material; and/or
    A curing chamber configured to cure the heated graphene modified fiber reinforcement material.
  12. The apparatus of claim 9, further comprising a fiber bundle shaping rack disposed between the creel and the injection molding box for adjusting the relative position between the fiber bundles.
  13. The apparatus according to claim 9, wherein the volume of the glue-pouring trough is equal to or less than 100 liters, preferably equal to or less than 50 liters.
  14. The apparatus of claim 9, wherein the injection molding box further has an agitation device configured to uniformly distribute the graphene in the matrix.
  15. A graphene modified fibre reinforced material manufactured using the method according to one of claims 1 to 8.
  16. A spar for a wind turbine blade having the graphene modified fibre reinforcement material of claim 15.
CN201980042146.3A 2019-11-13 2019-11-13 Method and equipment for manufacturing graphene modified fiber reinforced material Pending CN113115589A (en)

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Application publication date: 20210713