CN114286891B - Main beam for fan blade and manufacturing method thereof - Google Patents

Main beam for fan blade and manufacturing method thereof Download PDF

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Publication number
CN114286891B
CN114286891B CN202080003490.4A CN202080003490A CN114286891B CN 114286891 B CN114286891 B CN 114286891B CN 202080003490 A CN202080003490 A CN 202080003490A CN 114286891 B CN114286891 B CN 114286891B
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China
Prior art keywords
carbon fiber
glass fiber
pultruded
blade
plates
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CN202080003490.4A
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Chinese (zh)
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CN114286891A (en
Inventor
梁嫄
马豪
拉尔斯.欧佛高
孙建旭
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Envision Energy Co Ltd
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Envision Energy Co Ltd
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    • 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
    • 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
    • F03D1/065—Rotors characterised by their construction elements
    • F03D1/0675—Rotors characterised by their construction elements of the blades
    • 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
    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/20—Inorganic materials, e.g. non-metallic materials
    • F05B2280/2006—Carbon, e.g. graphite
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/60—Properties or characteristics given to material by treatment or manufacturing
    • F05B2280/6003—Composites; e.g. fibre-reinforced
    • 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
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Textile Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Wind Motors (AREA)

Abstract

A main girder (100) for a fan blade (1) and a method of manufacturing the same, comprising: one or more carbon fiber pultrusion plates (101) arranged along the length direction of the blade (1); one or more glass fiber pultrusion panels (102) arranged along the length direction of the blade (1), wherein the carbon fiber pultrusion panels (101) and the glass fiber pultrusion panels (102) are mixed and arranged such that the mixed carbon fiber pultrusion panels (101) and glass fiber pultrusion panels (102) have a positive hybrid effect and/or a kink coupling effect; a kind of electronic device with high-pressure air-conditioning system; a first potting material impregnating the carbon fiber pultruded panels (101) and the glass fiber pultruded panels (102).

Description

Main beam for fan blade and manufacturing method thereof
Technical Field
The invention relates to the field of wind driven generators, in particular to a main beam for a fan blade. The invention further relates to a method for producing such a girder.
Background
In recent years, with the increasing importance of various countries to the environment, the clean energy field has a trend of rapid development worldwide. As a novel energy source, the clean energy source has the advantages of wide distribution, reproducibility, small environmental pollution and the like compared with the traditional fossil fuel. Wind power generators are increasingly being used as the most potential representative of clean energy sources and are expected to further replace traditional fossil energy sources. Wind power is a typical clean energy source, and in recent years, environmental protection problems are increasingly emphasized by all parties. The core and soul of wind power are blade designs, and the key of the blade designs depends on a main bearing structure-main beam design.
The blades of the wind driven generator are important components for capturing wind energy of the wind driven generator, wherein the blades arranged on the hub of the wind driven generator rotate under the drive of wind energy to generate lift force, and the lift force is further converted into torque through a transmission chain in the cabin to drive the generator to generate power. Under the same condition, the larger the impeller formed by the blades is, the more wind energy can be captured, so that the blades of the fan have a trend of longer and longer. As blades become longer and longer, clearance (clearance refers to the distance from the tip of a fan blade to the tower, an important safety indicator) is becoming a bottleneck, and development of new blade materials or blade designs to improve clearance has become urgent. The blade spar acts as a component contributing about 90% of the flapwise stiffness, thereby substantially determining the size of the clearance.
Carbon fiber is a high modulus, high strength material, but at the same time is relatively expensive. Therefore, how to reasonably introduce carbon fibers into blades to achieve the aims of improving the clearance margin and increasing the cost of the blades as little as possible is an important research topic at present for each large wind power company. Because the cost of the pure carbon fiber main beam is too high, the cost is input for too long at one time, and thus, the mixed fiber material is generated. The hybrid fiber material is a composite material obtained by braiding or laying a certain amount of carbon fibers and glass fibers. Hybrid fiber materials can balance performance and cost as much as possible.
However, current hybrid fiber materials have mainly the following limitations:
1. the mixing mode of the mixed fiber material is mostly carried out on the material scale, for example, carbon fibers and glass fibers are mixed and woven on the same fabric layer according to different proportions of fiber bundles, or one layer of carbon fibers and one layer of glass fibers are mixed and paved, the mixed mode is extremely lack of design freedom, the mixed proportion of the fibers is completely limited by a material provider, and for different types of blades, only fixed mixed proportion materials can be selected, so that the requirement of customizing for each type of blade cannot be met.
2. The final mechanical properties of carbon fibers are greatly affected by the process, so that a stable process route is critical to the performance stability of the final product. The hybrid fiber material (i.e. the hybrid material of carbon fiber and glass fiber) generally adopts a pouring process, i.e. the carbon glass hybrid fabric is poured together by stacking multiple layers, or by stacking several layers of carbon fiber and several layers of glass fiber cloth. However, the pouring process of this material is prone to defects such as bubbles and wrinkles, which are detrimental to the final properties.
There is a need for a new fan girder or girder material that at least partially obviates the above-described limitations.
Disclosure of Invention
The object of the invention is to provide a girder for a fan blade and a method for producing the same, by means of which, with reduced carbon fiber consumption, a more economical, better performance and a more operable hybrid form can be produced, so that the required stiffness and the service life of the girder are increased.
In a first aspect of the invention, the object is achieved by a girder for a fan blade, comprising: one or more carbon fiber pultruded panels aligned along the length of the blade; one or more glass fiber pultruded panels arranged along the length of the blade; the carbon fiber pultruded panel and the glass fiber pultruded panel are combined in one or more ways and combined and mixed in one or more proportions so that the mixed carbon fiber pultruded panel and glass fiber pultruded panel have a positive mixing effect and/or a bending-twisting coupling effect; and a first potting material impregnating the carbon fiber pultruded panel and the glass fiber pultruded panel.
In the present invention, the term "spar" refers to an elongated structure in the shell on both sides of the blade for reinforcing the blade. Typically, the two side girders are connected to webs located inside the blade to support the interior space of the blade. The carbon fiber pultrusion plate refers to a material formed by impregnating carbon fibers with resin and extruding through Cheng Guhua, and the glass fiber pultrusion plate refers to a material formed by impregnating glass fibers with resin and extruding through Cheng Guhua. Preferably, the carbon fiber pultruded panels and the glass fiber pultruded panels in the main beam together form a continuous main beam surface having a desired curvature when necessary. The term "infiltration" refers to pouring of the casting material into the casting object and at least partially bonding and final curing thereof. In addition, the second pouring material forming the carbon fiber pultrusion plate can be the same as the first pouring material, and can also be other pouring materials, and similarly, the third pouring material forming the glass fiber pultrusion plate can be the same as the first pouring material, and can also be other pouring materials; the carbon fiber pultruded panels and the glass fiber pultruded panels may be disposed adjacent to each other in a direction perpendicular to the thickness of the main beam, such as in the length and width directions of the main beam, to form a coverage area of the main beam. In the case where the carbon fiber pultruded panel and the glass fiber pultruded panel are in a strip-like structure, the carbon fiber pultruded panel and the glass fiber pultruded panel may be disposed adjacent to each other in a chord direction of the main beam. As used herein, the term "chordwise" refers to a direction perpendicular to the thickness of the spar and perpendicular to the length of the blade.
In one embodiment of the invention, the glass fiber pultruded panel body has a rectangular cross section. Glass fiber pultruded panels of different sizes may be employed depending on the application. For example, the dimensions of the fiberglass pultruded panel may be determined according to the desired final shape of the main beam.
In one embodiment of the invention, the carbon fiber pultruded panel body has a rectangular cross section. Depending on the application, carbon fiber pultruded panels of different sizes may be employed. For example, the dimensions of the carbon fiber pultruded panels may be determined according to the desired final shape of the main beam.
In one embodiment of the invention, it is provided that m carbon fiber pultruded panels are stacked in the thickness direction of the blade and/or n carbon fiber pultruded panels are stacked in the chord direction of the blade in a certain region of the main girder, wherein m and n are integers from 1 to 100. The carbon fiber pultruded panels extend between 0.1% and 99.9% of the blade length. The starting point of the length of the blade is the joint of the root of the blade and the hub, and the end point of the length of the blade is the blade tip.
In a further embodiment of the invention, it is provided that in a region of the main girder, p glass fiber pultrusions are stacked in the thickness direction of the blade and/or q glass fiber pultrusions are stacked in the chord direction of the blade, wherein p and q are integers from 1 to 100.
For example, one or more glass fiber pultruded panels may be disposed above, below, right and left, front and back, and/or one or more carbon fiber pultruded panels may be disposed. Similarly, one or more glass fiber pultruded panels may be disposed above, below, left and right, front and rear, and/or one or more carbon fiber pultruded panels may be disposed above, below, left and right, front and rear, each glass fiber pultruded panel. By adjusting the different mixing schemes, mixing dimensions, and mixing ratios of the carbon fiber pultruded panels and the glass fiber pultruded panels, the stiffness of the main beam can be adjusted so that the glass fiber pultruded panels and the carbon fiber pultruded panels together achieve the desired flap stiffness after secondary infusion and better form the desired curved surface.
In another preferred embodiment of the present invention, it is provided that the carbon fiber pultruded panel is cured using the second potting material, and the glass fiber pultruded panel is cured using the third potting material. The first pouring material, the second pouring material and the third pouring material can be the same or different from each other, or all the first pouring material, the second pouring material and the third pouring material are the same or different from each other, and all the first pouring material, the second pouring material and the third pouring material comprise one or more of the following materials: comprises thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenolic resin, bismaleimide and thermoplastic resin. Other castable materials are also contemplated under the teachings of the present invention.
In a further preferred aspect of the present invention, it is provided that the thermoplastic resin comprises one or more of the following: polypropylene resin, polyethylene resin, polyvinyl chloride resin, polystyrene resin, polyacrylonitrile-butadiene-styrene resin, polyurethane, polyimide resin, polyether ether ketone resin, and polyphenylene sulfide resin. Other thermoplastic resins are also contemplated under the teachings of the present invention.
In a further development of the invention, it is provided that, on one or more layers in the thickness direction of the blade, a first end of the carbon fiber pultruded panel is connected to a second end of the glass fiber pultruded panel and/or that a first end of the carbon fiber pultruded panel is inserted between two of the glass fiber pultruded panels and/or that a second end of the glass fiber pultruded panel is inserted between two of the carbon fiber pultruded panels. The first end and the second end may be ends located in the length direction of the glass fiber pultruded plate and the carbon fiber pultruded plate, or may be ends located in the width direction of the glass fiber pultruded plate and the carbon fiber pultruded plate.
Through the preferred scheme, better passive load shedding of the main beam can be realized, for example, a certain layer in the thickness direction of the blade is designed to be in specific hybrid arrangement along the chord direction, a first carbon fiber pultrusion plate and a first glass fiber pultrusion plate which are locally connected are distributed on a first chord direction coordinate position, a second carbon fiber pultrusion plate and a second glass fiber pultrusion plate which are locally connected are distributed on a second chord direction coordinate position, and the like, and an Nth carbon fiber pultrusion plate and an Nth glass fiber pultrusion plate which are locally connected are distributed on an Nth chord direction coordinate position, so that the connection part on the first chord direction coordinate position, the connection part on the second chord direction coordinate position and the connection part on the Nth chord direction coordinate position can be distributed in a staggered manner, the blade can have a bending coupling effect, namely torsion deformation is generated under the condition of being bent, and the load shedding is passively by utilizing the response of the structure.
In a further preferred embodiment of the invention, it is provided that at the connection point of the glass fiber pultruded panel and the carbon fiber pultruded panel, one or more connection sections are provided, which cover the first end of the carbon fiber pultruded panel and/or the second end of the glass fiber pultruded panel.
Through this preferred scheme, can realize the better local intensity of girder, and provide gentle geometric transition, its reason is, at first, from junction, carbon fiber pultrusion board and glass fiber pultrusion board both sides all have the chamfer to transition from 0 to full thickness, lay multilayer fiber cloth about the blank region of junction respectively, the staggered floor size of fiber cloth matches with the slope angle of both sides pultrusion board, the carbon fiber pultrusion board of local connection utilizes the cloth layer of junction to connect with glass fiber pultrusion board, both satisfy intensity and satisfy the requirement of geometric gentle transition again, when the chamfer side of two pultrusion boards is towards one side, the fiber cloth is from nearest to junction of two pultrusion boards to when full transition to full thickness, the size of fiber cloth is little to big gradual. When the chamfer angles of the two pultrusion plates face to two sides, the two pultrusion plates are butted to form slope angle matching, the multi-layer fiber cloth is arranged between the two plates, the gap between the two pultrusion plates is not present, the laminating degree is better, the friction coefficient is increased, the two pultrusion plates do not move in a dislocation way, and the local rigidity is enhanced; in addition, the upper surface of the upper plate and the lower surface of the lower plate are respectively provided with a layer of fiber cloth and a layer of fiber cloth, and the whole is formed into a local connection design, so that the upper surface and the lower surface of the two pultruded plates are smoother. Since the main girder is formed by two pultruded panel main bodies and the connecting part of the two main girders in the thickness direction, more mobility is provided in the direction perpendicular to the thickness direction of the main girder, such as the chord direction; these mobility properties facilitate the desired surface shape, such as a curved surface, of the main beam material prior to infusion, and thus may be cured to maintain the surface shape after infusion.
In a further preferred embodiment of the invention, it is provided that the connection comprises one or several of glass fiber fabric, carbon fiber fabric, glass fiber nonwoven fabric, carbon fiber nonwoven fabric, and glass fiber roving, and other connection materials are conceivable under the teachings of the invention. j connecting parts are stacked along the thickness direction of the blade, and/or k connecting parts are stacked along the chord direction of the blade, wherein j and k are integers of 1 to 100.
In a second aspect of the invention, the aforementioned task is solved by a method of manufacturing a main girder for a fan blade, comprising the steps of: providing one or more carbon fiber pultrusion plates, and arranging the carbon fiber pultrusion plates along the length direction of the blade; providing one or more glass fiber pultrusion plates, and arranging the glass fiber pultrusion plates along the length direction of the blade; mixing the carbon fiber pultruded panel and the glass fiber pultruded panel in one or more ways and in one or more proportions such that the mixed carbon fiber pultruded panel and glass fiber pultruded panel have a positive mixing effect and/or a kink coupling effect; and infiltrating the carbon fiber pultruded panel and the glass fiber pultruded panel with a first potting material.
In a preferred embodiment of the invention, provision is made for one or more carbon fiber pultruded panels and for one or more glass fiber pultruded panels to comprise the following steps: the carbon fiber pultruded plate is infiltrated and cured by using a second pouring material, and the glass fiber pultruded plate is infiltrated and cured by using a third pouring material; arranging one or more carbon fiber pultruded plates and/or glass fiber pultruded plates on top of each other, and arranging a pouring layer around each carbon fiber pultruded plate for secondary pouring; and arranging a pouring layer around each glass fiber pultrusion plate for secondary pouring.
The invention has at least the following beneficial effects: (1) The invention adopts carbon fiber pultrusion and glass fiber pultrusion to mix, solves the defect of insufficient rigidity of the pure glass fiber main beam, and also avoids the defect of overhigh price of the pure carbon fiber; the mixing proportion of the carbon fiber and the glass fiber can be arbitrarily regulated to achieve the overall optimal cost performance; (2) The carbon fiber and glass fiber composite materials exist in their respective optimal process modes: carrying out pultrusion; the hybrid material has a positive hybrid effect, namely, the rigidity of the hybrid material is improved due to the existence of the other side, which is superior to a theoretical value of a pure mixing relation; compared with a pure carbon fiber pultrusion blade, the glass fiber mixing and buffering effects are achieved, so that the process sensitivity of the carbon fiber is reduced, and the process and quality robustness of the carbon fiber are improved; (3) The special local connection design can enable the carbon fiber pultrusion plate to start from the blade, and the local connection design has two functions, namely ensuring that the local strength of the connection meets the requirement, and providing gentle geometric transition to avoid the defects of resin enrichment and the like caused by suspending the pultrusion plate; the carbon fiber pultrusion plate and the glass fiber pultrusion plate can be mixed in the same layer according to the design, can also be mixed in different layers, have a local connection design, and can be arranged in any combination to the greatest extent; the local connection design is realized by a composite cloth layer, and a soft layer is used for connecting two hard structures, so that the method is flexible and proper.
The invention also provides a method of manufacturing a fan blade comprising the steps of: prefabricating the main girder by the method, placing the main girder in a shell, and pouring the main girder with the shell for the third time; or providing one or more carbon fiber pultruded plates, and arranging the carbon fiber pultruded plates in the shell along the length direction of the blade; providing one or more glass fiber pultrusion plates, and arranging the glass fiber pultrusion plates in the shell along the length direction of the blade; and (3) performing secondary pouring to integrally mold the carbon fiber pultrusion plate, the glass fiber pultrusion plate and other materials. The hybrid girder can be used as a prefabricated girder and is formed before the shell, and then is placed into the shell for secondary pouring; or the two pultruded panels may be initially placed into the housing and formed once with the rest of the housing.
In the main girder for the fan blade and the manufacturing method thereof, provided by the invention, the carbon fiber is a material with high specific strength and high specific modulus, is high in price, and is limited to be widely applied. Thus, the present invention achieves the most efficient use of carbon fiber materials. The carbon fiber and the glass fiber are mixed, so that the method is a more optimal design mode. Compared with the material-level hybridization of carbon glass hybridization braiding or carbon glass hybridization layering, the invention can lead to larger design space from higher dimension hybridization without being limited by material customization hybridization ratio. In addition, each performance of the carbon fiber is very sensitive to the process stability, and the pultrusion process is currently known to exert the performance of the carbon fiber material to the greatest extent and stably, and the glass fiber pultrusion can also stabilize the performance of the solidified glass fiber material. In summary, the carbon fiber pultrusion and glass fiber pultrusion material hybrid main beam can exert the maximum potential of blade design, and create the product with optimal cost performance.
Drawings
FIGS. 1A-1G illustrate various embodiments of a main beam according to the present invention;
FIGS. 2A-2C illustrate schematic views of the connection of various components in the main beam; and
FIGS. 3A-3B show schematic views of fans employing a main beam according to the present invention; and
fig. 4 shows a method flow of manufacturing a spar for a fan blade according to the present invention.
The figure shows: 100-main beams; 101-carbon fiber pultruded panels; 102-glass fiber pultruded plates; 103-a connection; 104-connection site.
Detailed Description
It should be noted that the components in the figures may be shown exaggerated for illustrative purposes and are not necessarily to scale. In the drawings, identical or functionally identical components are provided with the same reference numerals.
In the present invention, unless specifically indicated otherwise, "disposed on …", "disposed over …" and "disposed over …" do not preclude the presence of an intermediate therebetween. Furthermore, "disposed on or above" … merely indicates the relative positional relationship between the two components, but may also be converted to "disposed under or below" …, and vice versa, under certain circumstances, such as after reversing the product direction.
In the present invention, the embodiments are merely intended to illustrate the scheme of the present invention, and should not be construed as limiting.
In the present invention, the adjectives "a" and "an" do not exclude a scenario of a plurality of elements, unless specifically indicated.
It should also be 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 the components or assemblies may be added as needed for a particular scenario under the teachings of the present invention.
It should also be noted herein that, within the scope of the present invention, the terms "identical", "equal" and the like do not mean that the two values are absolutely equal, but rather allow for some reasonable error, that is, the terms also encompass "substantially identical", "substantially equal". By analogy, in the present invention, the term "perpendicular", "parallel" and the like in the table direction also covers the meaning of "substantially perpendicular", "substantially parallel".
The numbers of the steps of the respective methods of the present invention are not limited to the order of execution of the steps of the methods. The method steps may be performed in a different order unless otherwise indicated.
Most conventional spar are made of glass fiber reinforced plastic composite (GFRP) and are injection molded in a single spar mold to form a preform that is then placed into a shell mold to be assembled with other materials into an integral blade shell.
Most of the existing glass fiber main beams in the market are pure glass fiber main beams, the glass fiber materials cannot meet the requirement of the long blades on rigidity above 80m, so that the glass fiber blades are often extremely heavy, and the problem of rigidity can be effectively solved by adding the carbon fiber materials. However, the current carbon fiber main beam is only a pure carbon fiber pultrusion main beam or a pure carbon fiber pouring main beam, and the price is extremely high; even the carbon glass hybrid girder is in a material grade hybrid form of carbon glass hybrid braiding or hybrid laying, and the mixed arrangement of carbon materials and glass fiber materials is not carried out in a higher structural design dimension. In addition, even if the individual patents mention a hybrid design of carbon fiber and glass fiber pultrusion, the detailed design problem of the actual two material connection is not solved, and there is a lack of operability.
The object of the invention is to provide a girder for a fan blade and a method for producing the same, by means of which, with reduced carbon fiber consumption, a more economical, better performance and a more operable hybrid form can be produced, so that the required stiffness and the service life of the girder are increased.
To achieve the above-described idea, the present invention provides a girder for a fan blade and a method of manufacturing the same, including one or more carbon fiber pultruded panels arranged along a length direction of the blade; one or more glass fiber pultruded panels arranged along the length of the blade, wherein the carbon fiber pultruded panels and the glass fiber pultruded panels are mixedly arranged such that the mixed carbon fiber pultruded panels and glass fiber pultruded panels have a positive hybrid effect and/or a kink coupling effect; and; and the first pouring material is used for infiltrating the carbon fiber pultruded plate and the glass fiber pultruded plate.
The girder for a fan blade and the method of manufacturing the same according to the present invention will be described in further detail with reference to the accompanying drawings and specific embodiments. Advantages and features of the invention will become more apparent from the following description and from the claims. It should be noted that the drawings are in a very simplified form and are all to a non-precise scale, merely for convenience and clarity in aiding in the description of embodiments of the invention.
Whether the carbon plates are arranged at the outermost side of the blade or at the intermediate layer (the dimension in the thickness direction of the girder) can be determined according to the design optimization results, see the first embodiment and the second embodiment. Fig. 1A shows a first embodiment according to the invention.
In a first embodiment, the main beam includes: one or more carbon fiber pultruded panels 101, the carbon fiber pultruded panels 101 being arranged along the length z of the blade; one or more fiberglass pultruded panels 102, said fiberglass pultruded panels 102 also aligned along said blade length direction z, including: the length of the blade can be 0.1% -99.9% by splicing a plurality of plates, and the length of the blade can be 0.1% -99.9% by splicing a whole plate. The starting point of the length of the blade is the joint of the root of the blade and the hub, and the end point of the length of the blade is the blade tip. The carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 extend for 0.1% -99.9% of the blade length. Under the teachings of the present invention, the carbon fiber pultruded panels 101 and glass fiber pultruded panels 102 start at 0.1% -99.9% of the blade length and the carbon fiber pultruded panels 101 and glass fiber pultruded panels 102 end at 0.1% -99.9% of the blade length.
In a certain area of the main beam, 3 carbon fiber pultrusion plates 101 are stacked along the thickness direction x of the blade, in a certain area of the main beam, 7 glass fiber pultrusion plates 102 are stacked along the thickness direction x of the blade, and as seen from the side view, the carbon fiber pultrusion plates 101 are arranged at the outermost side of the blade, and the glass fiber pultrusion plates 102 are arranged at the inner side of the blade; the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 are mixed in one or more modes and one or more proportion combinations; a second potting material, which wets the carbon fiber pultruded panel 101, and a third potting material, which wets the fiberglass pultruded panel 102.
The glass fiber pultruded panels 102 have a rectangular cross-section. Different sized glass fiber pultruded panels 102 may be used depending on the application. For example, the dimensions of the glass fiber pultruded panels 102 may be determined according to the desired final shape of the main beam. The carbon fiber pultruded panel 101 has a rectangular cross section. Depending on the application, different sizes of carbon fiber pultruded panels 101 may be used. For example, the carbon fiber pultruded panels 101 may be sized according to the desired final shape of the main beam.
Fig. 1B shows a second embodiment according to the invention.
In the second embodiment, one or more glass fiber pultrusion panels 102 are arranged above and below each carbon fiber pultrusion panel 101. The carbon fiber pultrusion plate is arbitrarily embedded into the glass fiber pultrusion plate, and the rigidity of the main beam can be adjusted by adjusting different mixing schemes, mixing sizes and mixing proportions of the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102, so that the glass fiber pultrusion plate 102 and the carbon fiber pultrusion plate 101 together realize the desired waviness rigidity after secondary pouring and better form a desired curved surface.
In another preferred embodiment of the present invention, it is provided that the carbon fiber pultrusion panel 101 is cured by the second potting material, and the glass fiber pultrusion panel 102 is cured by the third potting material. Wherein the first infusion material, the second infusion material, and the third infusion material each comprise one or more of: comprises thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenolic resin, bismaleimide and thermoplastic resin. Other castable materials are also contemplated under the teachings of the present invention.
In a further preferred aspect of the present invention, it is provided that the thermoplastic resin comprises one or more of the following: polypropylene resin, polyethylene resin, polyvinyl chloride resin, polystyrene resin, polyacrylonitrile-butadiene-styrene resin, polyurethane, polyimide resin, polyether ether ketone resin, and polyphenylene sulfide resin. Other thermoplastic resins are also contemplated under the teachings of the present invention.
In a further development of the invention, it is provided that on one or more layers in the blade thickness direction x, a first end of the carbon fiber pultrusion plate 101 is connected to a second end of the glass fiber pultrusion plate 102, and/or that a first end of the carbon fiber pultrusion plate 101 is inserted between two of the glass fiber pultrusion plates 102, and/or that a second end of the glass fiber pultrusion plate 102 is inserted between two of the carbon fiber pultrusion plates 101. The first end portion and the second end portion may be end portions located in the longitudinal direction z of the glass fiber pultrusion plate 102 and the carbon fiber pultrusion plate 101, or may be end portions located in the width direction of the glass fiber pultrusion plate 102 and the carbon fiber pultrusion plate 101.
It is possible to determine whether or not the carbon plates are arranged at the most tip portion (dimension in the blade length direction) of the blade based on the design optimization result, see the third embodiment and the fourth embodiment.
Fig. 1C shows a third embodiment according to the invention.
In the third embodiment, the carbon fiber pultrusion panel 101 is inserted and connected on the same side of the glass fiber pultrusion panel 102. The carbon fiber pultrusion plate 101 is arranged only in the tip region, and the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 are in-layer hybrid.
Fig. 1D shows a fourth embodiment according to the invention.
In the fourth embodiment, a short carbon fiber pultrusion panel 101 is inserted between two long glass fiber pultrusion panels 102. The carbon fiber pultrusion plate 101 is arranged only in the tip region, and the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 are mixed between layers.
Fig. 1E shows a fifth embodiment according to the present invention.
In the fifth embodiment, 3 carbon fiber pultrusions 101 are placed on the first layer, 2 carbon fiber pultrusions 101 are placed on the second layer, 1 carbon fiber pultrusion 101 is placed on the third layer, and different numbers of carbon fiber pultrusions 101 are distributed in the chord direction, so that the torsion and shearing center of each layer can generate chord direction deflection, the main girder can generate torsion deformation when being subjected to bending load, and the attack angle of the blade can be reduced due to the increase of the torsion negative direction, thereby having the load reducing effect.
Fig. 1F shows a sixth embodiment according to the present invention.
In the sixth embodiment, on each layer (which should have a plurality of carbon fiber pultruded panels 101) in the fifth embodiment, the carbon fiber pultruded panels 101 and the glass fiber pultruded panels 102 are macroscopically straight butt-jointed.
Fig. 1G shows a seventh embodiment according to the present invention.
Unlike the sixth embodiment, in the seventh embodiment, the carbon fiber pultrusion panel 101 and the glass fiber pultrusion panel 102 are macroscopically zigzag-shaped, and the zigzag-shaped butt joint can reduce the damage caused by local stress abrupt changes.
Through the fifth embodiment, the sixth embodiment and the seventh embodiment, for example, in a layer in the thickness direction x of the blade, a specific hybrid arrangement is designed along the chord direction y, where the first carbon fiber pultrusion plate 101 and the first glass fiber pultrusion plate 102 that are distributed and partially connected are located at a first chord direction y coordinate position, the second carbon fiber pultrusion plate 101 and the second glass fiber pultrusion plate 102 that are distributed and partially connected are located at a second chord direction y coordinate position, and so on, where the nth carbon fiber pultrusion plate 101 and the nth glass fiber pultrusion plate 102 that are distributed and partially connected are located at an nth chord direction y coordinate position, the connection location 104 on the first chord direction y coordinate position, the connection location 104 on the second chord direction y coordinate position and the nth chord direction y coordinate position can be distributed in a staggered manner, so that the blade has a twisting coupling effect, that is, torsion deformation is generated under the condition of being bent, and the response of the structure is utilized to perform the passive load reduction.
In a further preferred embodiment of the invention, it is provided that at the connection 104 of the glass fiber pultruded panel 102 and the carbon fiber pultruded panel 101, one or more connection portions 103 are provided, said connection portions 103 covering the first end of the carbon fiber pultruded panel 101 and/or the second end of the glass fiber pultruded panel 102.
In a further preferred embodiment of the invention, it is provided that the connection comprises one or several of glass fiber fabric, carbon fiber fabric, glass fiber nonwoven fabric, carbon fiber nonwoven fabric, and glass fiber roving, and other connection materials are conceivable under the teachings of the invention. j connecting parts are stacked along the thickness direction x of the blade, and/or k connecting parts are stacked along the chord direction y of the blade, wherein j and k are integers from 1 to 100.
By means of the preferred scheme, better local strength of the main beam can be achieved, and gentle geometric transition is provided, and the reason is that firstly, starting from the connecting position 104, the two sides of the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 are respectively provided with chamfer angles to transition from 0 to full thickness, a plurality of layers of fiber cloth (connecting parts 103) are respectively paved on the upper side and the lower side of a blank area of the connecting position 104, the staggered layer size of the fiber cloth (the connecting parts 103) is matched with the slope angle of the two sides of the pultrusion plate, the locally connected carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 are connected by utilizing the cloth layer of the connecting part 104, the requirements of strength and the geometric gentle transition are met, and when the chamfer sides of the two pultrusion plates face one side, the size of the fiber cloth (the connecting parts 103) is gradually changed from small to large when the connecting position closest to the two pultrusion plates is completely transited to full thickness. When the chamfer angles of the two pultrusion plates face to two sides, the two pultrusion plates are butted to form slope angle matching, the multi-layer fiber cloth is arranged between the two plates, the gap between the two pultrusion plates is not present, the laminating degree is better, the friction coefficient is increased, the two pultrusion plates do not move in a dislocation way, and the local rigidity is enhanced; in addition, the upper surface of the upper plate and the lower surface of the lower plate are respectively provided with a layer of fiber cloth and a layer of fiber cloth, and the whole is formed into a local connection design, so that the upper surface and the lower surface of the two pultruded plates are smoother. Since it is made up of two pultruded panel bodies and the connection portion 104 of the two in the thickness direction x of the main beam, more mobility is provided in the direction perpendicular to the thickness direction x of the main beam, such as in the chordwise y direction; these mobility properties facilitate the desired surface shape, such as a curved surface, of the main beam material prior to infusion, and thus may be cured to maintain the surface shape after infusion.
The carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 are respectively provided with chamfers at two sides, the chamfers are transited from full thickness to 0, x layers of fiber cloth are respectively paved on the upper part and the lower part of a middle blank area, the staggered layer size of the fiber cloth is matched with the slope angle of the two side pultrusion plates, and the left and the right pultrusion plates are connected by utilizing the middle cloth layers, so that the strength and the requirement of geometric gentle transition are met.
Fig. 2A shows an eighth embodiment according to the invention.
In the eighth embodiment, the chamfer sides of the carbon fiber pultrusion panel 101 and the glass fiber pultrusion panel 102 face to one side, namely, the first connection mode of the carbon fiber pultrusion panel 101 and the glass fiber pultrusion panel 102 when mixed in the layer in the third embodiment, the fifth embodiment, the sixth embodiment and the seventh embodiment;
fig. 2B shows a ninth embodiment according to the present invention.
In the ninth embodiment, the chamfer angles of the carbon fiber pultrusion panel 101 and the glass fiber pultrusion panel 102 face to two sides, namely, the second connection mode when the carbon fiber pultrusion panel 101 and the glass fiber pultrusion panel 102 are mixed in the layer in the third embodiment, the fifth embodiment, the sixth embodiment and the seventh embodiment; there are x layers of fiber cloth between the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102, and there are y and z layers of fiber cloth (connecting portion 103) respectively on the upper side of the carbon fiber pultrusion plate 101 and the lower side of the glass fiber pultrusion plate 102, and the whole is formed into a local connection design.
Fig. 2C shows a tenth embodiment according to the present invention.
In the tenth embodiment, the carbon fiber pultrusion plate 101 has a chamfer, the glass fiber pultrusion plate 102 is smooth, i.e. in the fourth embodiment, the carbon fiber pultrusion plate 101 is inserted into the middle of the glass fiber pultrusion plate 102, and the first connection mode is the interlayer mixing; the carbon fiber pultrusion plate 101 is inserted into the middle of the glass fiber pultrusion plate 102, and reliable and gentle connection design is also needed, and y and x layers of cloth (connection part 103) are respectively arranged on the upper and lower sides of the carbon fiber pultrusion plate 101 to play a role of local connection.
In a second aspect of the invention, the aforementioned task is solved by a method of manufacturing a main girder for a fan blade, comprising the steps of: providing one or more carbon fiber pultrusion plates 101, and arranging the carbon fiber pultrusion plates 101 along the length direction z of the blade; providing one or more glass fiber pultruded panels 102, and arranging the glass fiber pultruded panels 102 along the length direction z of the blade; mixing the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 in one or more combinations and one or more proportional combinations; the carbon fiber pultruded panel 101 and the glass fiber pultruded panel 102 are infiltrated with a first potting material.
In a preferred embodiment of the present invention, providing one or more carbon fiber pultruded panels 101 and providing one or more glass fiber pultruded panels 102 comprises the steps of: the carbon fiber pultrusion plate 101 is infiltrated and cured with a second infusion material, and the glass fiber pultrusion plate 102 is infiltrated and cured with a third infusion material; disposing one or more carbon fiber pultruded panels 101 and/or glass fiber pultruded panels 102 on top of each other and providing a glass fiber infusion layer around each of said carbon fiber pultruded panels 101 for a second infusion; and disposing a glass fiber infusion layer around each of the glass fiber pultruded panels 102 for a second infusion.
The invention also provides a method of manufacturing a fan blade comprising the steps of: prefabricating the main girder by the method, placing the main girder in a shell, and pouring the main girder with the shell for the third time; or providing one or more carbon fiber pultrusion plates 101, and arranging the carbon fiber pultrusion plates 101 in the shell along the length direction z of the blade; providing one or more glass fiber pultruded panels 102, and arranging the glass fiber pultruded panels 102 in the shell along the length direction z of the blade; and (3) performing secondary pouring to integrally mold the carbon fiber pultrusion plate 101, the glass fiber pultrusion plate 102 and other materials. The hybrid girder can be used as a prefabricated girder and is formed before the shell, and then is placed into the shell for secondary pouring; or the two pultruded panels may be initially placed into the housing and formed once with the rest of the housing.
In the main girder for the fan blade and the manufacturing method thereof, provided by the invention, the carbon fiber is a material with high specific strength and high specific modulus, is high in price, and is limited to be widely applied. Thus, the present invention achieves the most efficient use of carbon fiber materials. The carbon fiber and the glass fiber are mixed, so that the method is a more optimal design mode. Compared with the material-level hybridization of carbon glass hybridization braiding or carbon glass hybridization layering, the invention can lead to larger design space from higher dimension hybridization without being limited by material customization hybridization ratio. In addition, each performance of the carbon fiber is very sensitive to the process stability, and the pultrusion process is currently known to exert the performance of the carbon fiber material to the greatest extent and stably, and the glass fiber pultrusion can also stabilize the performance of the solidified glass fiber material. In summary, the carbon fiber pultrusion and glass fiber pultrusion material hybrid main beam can exert the maximum potential of blade design, and create the product with optimal cost performance.
Fig. 3A shows a schematic cross-sectional view of a wind turbine blade 1 in a vertical blade thickness direction using a spar 100 according to the present invention.
Fig. 3B shows a schematic cross-sectional view of a vertical blade length direction of a wind turbine blade 1 employing a spar 100 according to the present invention.
As shown in fig. 3B, the blade 1 has a blade leading edge 2 and a blade trailing edge 8, and the portion of the blade 1 that is in front of the blade leading edge 2 and the blade trailing edge 8 is divided into a windward side 5 and a leeward side 6. The trailing edge beam 7 is arranged close to the trailing edge 8 to increase the trailing edge strength. The main beams 100 are arranged on the windward side 5 and the leeward side 6, respectively, between the blade leading edge 2 and the blade trailing edge 8. The girders 100 are connected by webs 4 to increase blade stability against inward collapse. By the girder 100 of the present invention, the rigidity of the blade 1 can be improved, and the compliance of the girder material can be enhanced, thereby improving the aerodynamic performance and the service life of the blade.
FIG. 4 illustrates a method flow 400 of manufacturing a spar for a fan blade in accordance with the present invention.
Providing one or more carbon fiber pultruded panels stacked in a thickness direction, a length direction and/or a chord direction, wherein the carbon fiber pultruded panels are cured with a second infusion material, wherein a glass fiber infusion material is arranged between every two carbon fiber pultruded panels, step 402;
At step 404, providing one or more fiberglass pultruded panels stacked in a thickness direction, a length direction, and/or a chord direction, wherein the fiberglass pultruded panels are cured with a third infusion material, wherein a fiberglass infusion material is disposed between each two fiberglass pultruded panels; which may be disposed adjacent to the carbon fiber pultruded panel;
at step 406, disposing one or more cover layers on the carbon fiber pultruded panel and/or the glass fiber pultruded panel on both sides of the main beam in the thickness direction; and
at step 408, the carbon fiber pultruded panels, glass fiber pultruded panels and cladding are infiltrated with a first potting material.
The invention has at least the following beneficial effects: (1) The invention adopts carbon fiber pultrusion and glass fiber pultrusion to mix, solves the defect of insufficient rigidity of the pure glass fiber main beam, and also avoids the defect of overhigh price of the pure carbon fiber; the mixing proportion of the carbon fiber and the glass fiber can be arbitrarily regulated to achieve the overall optimal cost performance; (2) The carbon fiber and glass fiber composite materials exist in their respective optimal process modes: carrying out pultrusion; the hybrid material has a positive hybrid effect, namely, the rigidity of the hybrid material is improved due to the existence of the other side, which is superior to a theoretical value of a pure mixing relation; compared with a pure carbon fiber pultrusion blade, the glass fiber mixing and buffering effects are achieved, so that the process sensitivity of the carbon fiber is reduced, and the process and quality robustness of the carbon fiber are improved; (3) The special local connection design can enable the carbon fiber pultrusion plate to start from the blade, and the local connection design has two functions, namely ensuring that the local strength of the connection meets the requirement, and providing gentle geometric transition to avoid the defects of resin enrichment and the like caused by suspending the pultrusion plate; the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 can be mixed in the same layer according to the design, can also be mixed in different layers, have a local connection design, and can be arranged in any combination to the greatest extent; the local connection design is realized by a composite cloth layer, and a soft layer is used for connecting two hard structures, so that the method is very flexible and proper;
In summary, the foregoing embodiments describe in detail different configurations of the main beam for a fan blade and the method for manufacturing the same, and of course, the present invention includes, but is not limited to, the configurations listed in the foregoing embodiments, and any modifications based on the configurations provided in the foregoing embodiments fall within the scope of the present invention. One skilled in the art can recognize that the above embodiments are illustrative.
In the present specification, each embodiment is described in a progressive manner, and each embodiment is mainly described in a different point from other embodiments, and identical and similar parts between the embodiments are all enough to refer to each other. For the system disclosed in the embodiment, the description is relatively simple because of corresponding to the method disclosed in the embodiment, and the relevant points refer to the description of the method section.
The above description is only illustrative of the preferred embodiments of the present invention and is not intended to limit the scope of the present invention, and any alterations and modifications made by those skilled in the art based on the above disclosure shall fall within the scope of the appended claims.

Claims (12)

1. A main beam for a fan blade, comprising:
one or more carbon fiber pultruded panels arranged along the length of the blade and having ends provided with chamfers transitioning from full thickness to 0;
One or more glass fiber pultruded plates which are arranged along the length direction of the blade and are provided with chamfers at the ends to transition from full thickness to 0, wherein on one or more layers of the thickness direction of the blade, the ends of the carbon fiber pultruded plates are connected with the ends of the glass fiber pultruded plates, and/or the ends of the carbon fiber pultruded plates are inserted between the two glass fiber pultruded plates, and/or the ends of the glass fiber pultruded plates are inserted between the two carbon fiber pultruded plates, so that the mixed carbon fiber pultruded plates and glass fiber pultruded plates have positive mixing effect and/or bending-twisting coupling effect, and at least one layer of fiber cloth is respectively paved on the upper part and the lower part of a blank area of the joint of the carbon fiber pultruded plates and the glass fiber pultruded plates, and the staggered layer size of the fiber cloth is matched with the slope angles of the carbon fibers or the glass fiber pultruded plates on two sides so as to connect the carbon fiber pultruded plates and the glass fiber pultruded plates; and
and the first pouring material is used for infiltrating the carbon fiber pultruded plate and the glass fiber pultruded plate.
2. The girder according to claim 1, wherein m carbon fiber pultruded panels are stacked in a thickness direction of the blade and/or n carbon fiber pultruded panels are stacked in a chord direction of the blade in a certain region of the girder, wherein m and n are integers of 1 to 100.
3. The girder according to claim 1, wherein p of said glass fiber pultruded panels are stacked in a thickness direction of the blade and/or q of said glass fiber pultruded panels are stacked in a chord direction of the blade in a certain area of said girder, wherein p and q are each integers of 1 to 100.
4. The girder of claim 1, wherein the carbon fiber pultruded panels are cured with a second potting material and the fiberglass pultruded panels are cured with a third potting material.
5. The girder of claim 4, wherein the first potting material comprises one or more of: comprises thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenolic resin, bismaleimide and thermoplastic resin;
the second potting material comprises one or more of: comprises thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenolic resin, bismaleimide and thermoplastic resin;
the third potting material comprises one or more of: comprises thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenolic resin, bismaleimide and thermoplastic resin.
6. The main beam of claim 5, wherein the thermoplastic resin comprises one or more of: polypropylene resin, polyethylene resin, polyvinyl chloride resin, polystyrene resin, polyacrylonitrile-butadiene-styrene resin, polyurethane, polyimide resin, polyether ether ketone resin, and polyphenylene sulfide resin.
7. The girder of claim 1, wherein the fiber cloths include one or more of glass fiber fabrics, carbon fiber fabrics, glass fiber non-woven fabrics, carbon fiber non-woven fabrics, and glass fiber rovings, j fiber cloths being stacked in a thickness direction of the blade, and/or k fiber cloths being stacked in a chord direction of the blade, wherein j and k are integers of 1 to 100.
8. The girder of claim 1, wherein said carbon fiber pultruded panels start at 0.1% -99.9% of the blade length and said carbon fiber pultruded panels end at 0.1% -99.9% of the blade length.
9. A method of manufacturing a spar for a fan blade, comprising the steps of:
providing one or more carbon fiber pultruded panels, wherein the end parts of the carbon fiber pultruded panels are provided with chamfers which transition from full thickness to 0, and the chamfers are arranged along the length direction of the blade;
Providing one or more glass fiber pultruded plates, wherein the end parts of the glass fiber pultruded plates are provided with chamfers which are transited from full thickness to 0, and the chamfers are arranged along the length direction of the blade;
connecting the ends of the carbon fiber pultruded plates with the ends of the glass fiber pultruded plates on one or more layers in the thickness direction of the blade, and/or inserting the ends of the carbon fiber pultruded plates between the two glass fiber pultruded plates, and/or inserting the ends of the glass fiber pultruded plates between the two carbon fiber pultruded plates, so that the mixed carbon fiber pultruded plates and glass fiber pultruded plates have a positive hybrid effect and/or a bending-torsion coupling effect;
at least one layer of fiber cloth is respectively paved on the upper part and the lower part of a blank area at the joint of the carbon fiber pultrusion plate and the glass fiber pultrusion plate, and the staggered layer size of the fiber cloth is matched with the slope angles of the carbon fibers or the glass fiber pultrusion plates at two sides so as to connect the carbon fibers and the glass fiber pultrusion plates; and
and infiltrating the carbon fiber pultruded panel and the glass fiber pultruded panel with a first potting material.
10. The method of claim 9, wherein providing one or more carbon fiber pultruded panels and providing one or more glass fiber pultruded panels comprises the steps of:
the carbon fiber pultruded plate is infiltrated and cured by using a second pouring material, and the glass fiber pultruded plate is infiltrated and cured by using a third pouring material;
Disposing one or more carbon fiber pultruded panels and/or glass fiber pultruded panels over each other, and
arranging a pouring layer around each carbon fiber pultrusion plate for secondary pouring; and
and arranging a pouring layer around each glass fiber pultrusion plate for secondary pouring.
11. A method of manufacturing a fan blade comprising the steps of:
prefabricating the girder by the method of claim 9, placing the girder in a shell, and performing a third pouring with the shell; or (b)
Providing one or more carbon fiber pultruded panels disposed within the housing along the length of the blade;
providing one or more glass fiber pultruded panels, and arranging the glass fiber pultruded panels in the shell along the length direction of the blade;
and (3) performing secondary pouring to integrally mold the carbon fiber pultrusion plate, the glass fiber pultrusion plate and other materials.
12. Wind power generator with a main girder according to one of the claims 1 to 8.
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CN109098929A (en) * 2017-06-21 2018-12-28 通用电气公司 The associated method of wind turbine blade and manufacture with hybrid spar caps
CN109094075A (en) * 2017-06-21 2018-12-28 通用电气公司 Wind turbine blade and related production with mixing spar caps
CN210859042U (en) * 2019-10-15 2020-06-26 中材科技风电叶片股份有限公司 Main beam cap splicing structure and fan rotor blade

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CN114286891A (en) 2022-04-05
GB2611677A (en) 2023-04-12

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