CN1644917A - Large pneumatic equipment blades made of composite material and production thereof - Google Patents

Large pneumatic equipment blades made of composite material and production thereof Download PDF

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Publication number
CN1644917A
CN1644917A CNA2005100234880A CN200510023488A CN1644917A CN 1644917 A CN1644917 A CN 1644917A CN A2005100234880 A CNA2005100234880 A CN A2005100234880A CN 200510023488 A CN200510023488 A CN 200510023488A CN 1644917 A CN1644917 A CN 1644917A
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blade
composite material
cloth
keel frame
fibre cloth
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CN100385113C (en
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黄争鸣
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Tongji University
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Tongji University
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/70Wind energy
    • Y02E10/72Wind turbines with rotation axis in wind direction
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50Manufacturing or production processes characterised by the final manufactured product

Abstract

A big-scale composite wind turbine blade characterized by once molding with entwined fiber as the strengthened materials and its fabricating method. The blade is composed by enhanced fiber, resin base, keel and couplings. The glue dipped fiber is put in a stair way in the lower blade mold, whereon the keels conjunct to each other and the keel on the rear part of the blade conjunct to the coupling. The cross section of the keels is similar to that of the blade. Correspondingly another layer of the glue dipped fiber is put in a stair way in the upper blade mold. The two parts of the blade mold are closed, sealed, vacuumed, injected into resin, heated to solidify and removed in steps to get the wind turbine blade.

Description

Large-scale composite wind turbine blades and its preparation methods
Technical field
The present invention relates to pneumatic equipment blades made, refer to a kind of Large-scale composite wind turbine blades and its preparation methods especially.
Background technique
Because the disposable energy (oil, coal etc.) is shortage more and more, the development and use of the recyclability energy become human common recognition, receive the very big concern of various countries.Wherein, wind energy is a kind of reproducibility energy that has business development to be worth at present most, will become an emphasis of China's energy exploitation and application.
Wind-power electricity generation is that the wind energy collecting that disperses is got up to do mechanical work, is converted into electric energy again, thereby can be directly utilized by the mankind.Blade occupies critical role in wind-driven generator.The design of blade and workmanship level are the key technology and the technical merit representative of wind-power generating system.By blade of wind-driven generator, the wind energy that unit energy density is lower can put together and form powerful rotating machinery merit, drives motor again, produces wind-powered electricity generation.Because the density of air is very little, blade of wind-driven generator must have enough big surface area, just may produce the scale and benefit of wind-powered electricity generation.Wind-power electricity generation and hydroelectric power are compared, because air density approximately is 1/180th of water density, suppose that wind speed is identical with the flow velocity of water, so, the power of desiring a typhoon power generator is provided is identical with the power that a hydraulic turbine generator provides, and the blade area of wind-driven generator just must be 180 times of hydraulic turbine generator blade area.Therefore, the blade of wind-driven generator all be usually very long (length of blade of MW class generally about 25 meters, 5 megawatts then above 60 meters), area is huge.So big huge monster only depends on fixed end to be suspended on the space running.How reducing the deadweight of blade, guarantee that simultaneously blade also has enough rigidity, intensity especially fatigue resistance and stability in the high wind field, is the key issue place that Blade Design and manufacturing face.
At present, blade of wind-driven generator, especially large-scale blade generally all are to adopt the composite material manufacturing, moulding process then is multistep processes (being the above composite material process planning of secondary or secondary) basically: the upper and lower shell for preparing earlier blade respectively (is generally glass fibre reinforced plastics, be the galss fiber reinforced resin based composites) and keel girder (normally continuous glass fibre or carbon fibre reinforced composite beam), and then adopt suitable technology (glue company, hand paste, mold pressing, hot pressing, injection molding etc.), be combined into a blade integral.Shell can be laminate or the middle honeycomb sandwich panel that accompanies foam or plank; Keel bar generally is hollow, so that alleviate structure weight.(application number: 20040253114) preparation technology of Jie Shaoing still belongs to the multistep method of forming to one piece of nearest U.S. Patent application.We know that in the composite material, reinforcing fiber mainly plays the load effect.Outer year that fiber is shared is many more, and the utilization ratio of composite material is just high more.On the other hand, one of main weakness of fibre reinforced composites is that switching performance is poor.At present, adopt any technology with two respectively the composite products of preparation couple together and all will cause its mechanical property to reduce greatly in the joint, thereby, influence the bearing capacity of integrated member.For the composite material blade shell, conventional method will go up lower casing separately manufacture after, can only lean on generally that resin glue is bonding to be integral.Since the intensity of resin glue only with the intensity equivalence of matrix, be significantly less than the intensity of composite material casing, thereby, shell after glue connects is about the same in the opening thin beam aspect bearing capacity, and its strength and stiffness will be far smaller than the intensity and the rigidity of the thin-walled beam of remaining silent of same material, identical cross-sectional shape, identical wall thickness.This is can only be with the basic reason of blade enclosure as time load spare in traditional multistep molding method for preparing.The role of main load-bearing part then generally will be born by the keel bar of additional configuration.
The problem that is produced is thus: keel bar must be continuous, almost is equal to the length of blade.Yet according to aerodynamic characteristic and loss of weight requirement, the cross section of blade should change along the length direction of blade.Such as, in the stressed maximum of the root of blade, vane thickness, cross section rigidity should be maximum, and blade tip thickness is then the thinnest; In addition, can be designed to maximum, blade tip chord length near the blade chord length of root then can be minimum.Therefore, adopt that the continuous fiber reinforced composite materials preparation is very long, the keel bar of hollow, variable cross section will become difficulty on technology, its difficulty is equal to the preparation of blade itself, promptly, generally will need two large-scale die cavitys: a preparation that is used for keel bar, another is used for last blade forming.Can make continuous fiber enhancing hollow tubular (circle, square type etc.) composite material overlength beam though pull technology (pultrusion) is pulled out in application, each cross section of beam must be identical.This prismatic keel bar not only makes the blade after the moulding be difficult to realize optimum design, promptly in the lightest design of satisfying under the conditions such as rigidity, intensity, stability of weight, but also need acquire the large-scale machine drawing of pulling out.In addition, composite material blade generally all need be buried link, metal connecting piece normally underground in its blade root portion, so that with the main drive shaft of vanes fixed to blower fan.In order to make being connected firmly between metal connecting piece and the keel bar, reliably, all need to use Stetch Wrapping Machine to manufacture the fiber reinforcing texture of keel bar usually.The special device spending that these have all increased during blade is manufactured has improved the manufacture cost of blade.
Summary of the invention
One of purpose of the present invention is to propose a kind of new Large-scale composite wind turbine blades and its preparation methods.Another object of the present invention is to propose a kind of new method of fixedlying connected that realizes between metal connecting piece and the wind machine's laminae made from composite material.
Technological scheme of the present invention comprises three key technologies.One of key technology is to replace repeatedly moulding with once-through in the preparation of large pneumatic equipment blades made of composite material, thereby, can guarantee the continuity of reinforcing fiber, improved integral rigidity, intensity and the stability of blade shell greatly.Two of key technology is not re-use extra keel bar as main load-bearing part, but directly by the blade enclosure carrying of sealing, makes material consumption reach minimum.The keel frame of core only plays in the blade preparation process supporting housing, further strengthens shell stability.This not only greatly facilitates the preparation of keel frame, and can guarantee the pneumatic external form of moulding rear blade with keel frame cross section by accurate pneumatic requirement design and processing.Because the keel frame needn't be along sharf to continuously, just can be implemented in root of blade easily and bury metal connecting piece securely underground, the loading transfer that also makes root is science, more firm more, because the bending resistance of this keel frame, Torsion Section modulus all are much higher than the section modulus value of traditional keel bar.Three of key technology is that to have adopted peripheral continuous textile sheet be reinforcing material, and enough rigidity and the intensity of composite material blade at axial direction can be provided, guarantee simultaneously along laterally promptly perpendicular to sharf to intensity.This not only is better than the enhancing effect of unidirectional composite material, also is being better than laminated plate structure aspect anti-interlayer shear, the anti-delamination, and is convenient to continuously shaped, the raising fibre cloth utilization ratio of reinforcing material.
The formant that constitutes wind machine's laminae made from composite material of the present invention has: cloth of reinforcement fibers, fluoropolymer resin (preferably intermediate temperature setting), keel frame, metal connecting piece etc., wherein metal connecting piece is used for fixing the main drive shaft of blade to wind energy conversion system.The capital equipment for preparing this wind machine's laminae made from composite material is die cavity and the fixture thereof that is divided into two, and comprises vacuum machine, pressure gauge, resin storage can, valve, and preferably also has heating system.The profile of leaf cross-section is consistent with the cross-sectional profile of die cavity cavity.By one or more fibers in carbon fiber, glass fibre, aramid fiber (Kevlar) fiber, graphite fiber, nylon fiber, ceramic fiber, the steel fiber, adopt Weaving method to be made into woven fibre cloth (wovenfabric), knitted fibers cloth (knitted fabric), textile sheet (braidedfabric), non-woven fibre cloth (non-woven fabric), to stitch one or more fibre cloth in the textured fiber cloth (stitchedfabric), but preferably textile sheet is used as reinforcing material.Keel frame cross section should be made the profile similar to leaf cross-section, can be discontinuous frame section, the processing of being more convenient for, preparation, but last head and the tail will have similar profile to blade after coupling together.The keel frame should light weight, inexpensive generally not as carrying usefulness.The rigidity and the intensity that are used for fixing the keel frame section (near the keel frame section of root of blade) of metal connecting piece should meet certain requirements, as solid wood, thin-wall metal, short fiber reinforced composite (casting) structure.Other keel frame section can adopt light weight, inexpensive materials processing to become hollow type, as adopting wooden splint and batten nail system, being mixed with the polymer of short fibre or directly by the polymer casting even can adopt foamed plastics and wooden frame etc.These each sections of keel frame glued joint from beginning to end with mighty bond and fuse.
Metal connecting piece forms with keel frame more than a section or a section near root of blade and fixedlys connected.One end of link can be metal flange, passes through bolt with the wind energy conversion system main drive shaft, and the centre is pipe or elliptical tube changeover portion, and the other end is a square tubular, and wherein square tubular partly passes keel frame section more than a section or a section.In the end of the last section keel frame that passes with pad, spiral shell nurse, the tail end of solid pin and link square tubular is fixed forever.
The preparation process of blade is described as follows.
It is stepped to hold the blade tip end to sprawl into from blade root in lower mode cavity the above fibre cloth of one deck (preferably textile sheet), and fibre cloth is impregnation in matrix in advance preferably, and temperature (50 ℃~400 ℃) cured resin is a body material in the employing.Between fibre cloth, also can arrange other fibre reinforced materials, as the unidirectional fibre prepreg.Then, all keel frame sections are joined end to end to be arranged in the lower mode cavity and to place on the fibre cloth that impregnation crosses, and the keel frame section of each separate machined links into an integrated entity discrete keel frame section with technology such as mighty bond, clench nails from beginning to end.If not link into an integrated entity, the keel frame section two ends with hollow structure that each section separation is arranged in the die cavity must be sealed, and fill with the resin of avoiding being injected in the die cavity.Must place an end end of die cavity with the fixing keel frame section of metal connecting piece.Fuse or tactic keel frame section on re-lay with lower mode cavity in fibre cloth according to this symmetry second half fibre cloth.With each layer fibre cloth respectively along periphery sew up, glue connects, overlapping or take and lean on, make the keel frame be wrapped in the fibre cloth (wherein some fibre cloth or other fibre reinforced materials such as unidirectional fibre prepreg also can be sewed up along periphery, glue connects, overlapping or take by).With upper cavity and lower mode cavity close up, fastening and along periphery sealing, vacuumize, injecting resin, intensification and take the circumstances into consideration pressurization, fibre cloth in the die cavity and sealing thereof thoroughly soaked into and solidify, after the demoulding, obtain one-time formed composite material blade.The textile sheet that also can adopt along the tubular of periphery closed (directly knitting forming) but have skylight (square tubular of being convenient to link passes) in the bottom is a reinforcing material.At this moment, must make the square tubular of link pass the skylight of all cloth of reinforcement fibers earlier, again the keel frame of square tubular and blade root be fixed.In addition, all the other each section keel frames also must be arranged in the textile sheet of tubular.Behind elder generation's daub, close up upper cavity again.
Description of drawings
Fig. 1,2 is mfg. moulding die of the present invention.
Fig. 3,4 is the means of fixation of keel frame section of the present invention and metal connecting piece.
Fig. 5,6 sprawl for fiber of the present invention.
Fig. 7 is a conjugate fiber cloth of the present invention.
Fig. 8 is preparation method's flow chart of the present invention.
Label declaration in the accompanying drawing:
The 1-lower mode cavity; The 2-fibre cloth;
3-keel frame; The 4-fibre cloth;
5-keel frame; The 6-flange;
The 7-link; 8-keel frame;
The 9-carbon fibre cloth; 10-fibre strip cloth;
The 11-glass fiber cloth; The 12-nylon cloth;
13-tubular fibre cloth; The 14-carbon fibre cloth;
The 15-nylon cloth.
Embodiment
Now further specify implementation process of the present invention as follows:
As illustrate shown in Figure 1, in lower mode cavity 1, layer overlay or multi-layer fiber cloth 2 are as the lower casing of blade, fibre cloth is impregnation in the resin of intermediate temperature setting in advance preferably, then, each section keel frame 3 is placed on the fibre cloth 2, it is joined end to end, see also schematic representation 2, wherein, near the keel frame section of blade root one end or plurality of sections keel frame 5 and metal connecting piece predetermined fixed together, see also schematic representation 3 and Fig. 4.Among the figure, 6 is flange, 7 is tubular connection, again fibre cloth 4 is layered on the top of keel frame 3, the number of plies of the number of plies of fibre cloth 4 and material and fibre cloth 2 and material be symmetry and also impregnation in advance fully, each respective layer in fibre cloth 4 and the fibre cloth 2 is stitched into one along periphery, last, cover upper cavity, pretension and along the sealing of die cavity periphery.Whole air of extracting out in the die cavity from the end of closed mould cavity one end form negative pressure, and the other end or the periphery from die cavity injects resin again, and fibre cloth 4, fibre cloth 2 and their peripheral sealing are all thoroughly soaked into.To die cavity pressurization or further fastening die cavity, extrude unnecessary resin.Simultaneously, to mold heated, the fibre cloth behind the impregnation is solidified under the temperature and pressure effect.Slough die cavity, obtain composite material wind-driven generator blade.
In light weight, outstanding advantages such as intensity is high, rigidity is big, good stability, technology is simple, processing and preparing is easy, cost is low that the wind machine's laminae made from composite material that obtains produced according to the present invention has will produce considerable social benefit and economic benefit.
Embodiment 1:
Metal (aluminum alloy, titanium alloy, stainless steel etc.) link 7 passes solid wooden keel frame 5, wherein the cross-sectional profile of the metal section of passing is square, the other end at the keel frame tightens up with pad, nut, and referring to schematic representation 3, keel frame profile is consistent with the cross-sectional profile of root of blade.The length of this solid keel frame (arrow direction) is limited, is no more than 0.5m.All the other each section keel frames 8 are all hollow wooden structures, are made by wooden splint and batten, and length is suitable.Behind all these keel frame end-to-ends, must be able to constitute the similar profile of blade to be prepared.Cross sectional representation 5 is seen in the laying of fibre cloth in lower mode cavity 1: impregnation (is the intermediate temperature setting resin in advance, 60 °~100 ° of solidifying temperatures) the multilayer carbon fiber woven cloth 9 after, 10 °~20 ° of braid angles, by 3k or the braiding of 6k yarn, the tail end braiding (or prefabricated) of fibre cloth is shape shown in the fibre cloth 10 into strips, and wherein the diameter of half slot is not more than the root diameter (RD) of metal connecting piece 7.These carbon fiber woven cloths along sharf to becoming stepped arrangement to blade tip by blade root, wherein the innermost layer fibre cloth is wanted to wrap whole core matter keel, skin at carbon fiber woven cloth 8, arrange layer of glass weave cloth 11 respectively, 10 °~20 ° of braid angles, yarn braiding by 100~200, and one deck nylon cloth 12, wherein glass fiber cloth 11 and nylon cloth 12 aim to provide the blade smooth surface after the curing, they all must more closely wrap whole blade, and this two layers of cloth is impregnation in advance also.After respectively each layer fibre cloth being sewed up along periphery, the upper cavity that closes, fastening, along the sealing of die cavity periphery.Extract the interior air of die cavity out from an end (as the point of blade) of closed mould cavity, a vacuum gauge is set at the other end (root of blade).After in vacuum gauge is presented at die cavity, having formed enough negative pressure of vacuum, open the valve that connects the splendid attire resin container, in die cavity, inject resin, thoroughly soak into each fibre cloth of its inside and fill up the die cavity gap.At last, further fastening up and down between die cavity, the little gap that compressing is reserved makes resin distribution evenly and extrude unnecessary resin.Intensification makes resin solidification to die cavity.After the die sinking, promptly obtain composite material blade.The shop number of plies of carbon fiber woven cloth 9 and along sharf to should being arranged to which kind of stairstepping, will determine by the load-up condition design.Initial design process is summarized as follows: the thickness identical (thickness of shell of different cross section is different) of any one cross section composite material casing of supposition blade, see this housing as the cross section of remaining silent.Before the design, to carry out fatigue bending test to same carbon fibre knitting cloth reinforced composite beam, determine the fatigue strength (when braid angle is not less than 40% and the radial line of weave cloth and the gap between parallel can ignore the time less than fiber volume fraction in 20 °, composite material, fatigue strength can be taken as half of static load intensity roughly) of material; According to design handbook, determine allowable stress again.According to moment of flexure, shearing and the centrifugal force of this cross section effect,, just be not difficult to determine the required thickness in this cross section based on the theory that cuts section bar of remaining silent in " mechanics of materials ".According to this thickness, make the shop number of plies (ignoring the contribution of glass fiber cloth 11 and 12 pairs of bearing capacitys of nylon cloth) of the needed weave cloth 9 in this cross section again.Should be noted that: determine bending fatigue strength the test material preparation condition must with the term harmonization of manufacturing of blade shell, especially to note spreading braid angle in the layer and the radial line in the weave cloth and want consistent with the gap between parallel.
Embodiment 2:
Embodiment 2 is substantially the same manner as Example 1, but each fibre cloth (being carbon fibre cloth 9, glass fiber cloth 11, nylon cloth 12) no longer is divided into two (seeing 10 in the schematic representation 5), but is made into cylindric shown in 13 in the schematic representation 6.The preparation process of blade is identical with example 1 description.
Embodiment 3:
Embodiment 3 is substantially the same manner as Example 1, just with some inner fiber cloth by preparation shown in Figure 7, wherein 14 be that carbon fibre cloth, 15 are nylon cloth, is stitched into one each other.Adopting this conjugate fiber cloth, is to be convenient to realize that blade shell thickness changes on request along the cross section contour.Because the air foil shape of blade profile, a side is that stressed district is then stressed less at the opposite side of wind sheltering facining the wind.Therefore, the composite material blade of optimal design not only sectional shape is different, and also should change at the thickness of same cross section inner housing: windward side is thick, the wind sheltering side thin.Use fibre cloth shown in Figure 7, nylon cloth is arranged in the wind sheltering side, just can achieve the goal.

Claims (10)

1, a kind of large pneumatic equipment blades made of composite material is made up of keel frame, reinforcing material, resin and link, it is characterized in that:
Contain in the reinforcing material of blade one or more layersly be wrapped on cross-sectional profile and the similar keel frame of blade profile, the one or more combination in the carbon fiber that periphery links to each other, glass fibre, aramid fibre, graphite fiber, nylon fiber, ceramic fiber, steel fiber textile cloth.
2, large pneumatic equipment blades made of composite material according to claim 1 is characterized in that:
Described textile fibre cloth comprises woven fibre cloth, knitted fibers cloth, establishment fibre cloth, non-woven fibre cloth, seam textured fiber cloth, but preferably works out fibre cloth.
3, large pneumatic equipment blades made of composite material according to claim 1 is characterized in that:
Used textile fibre cloth along the continuous mode of blade periphery comprise closure, stitching, glue connect, overlapping or take and lean on.
4, large pneumatic equipment blades made of composite material according to claim 1 is characterized in that:
The fibre cloth of described reinforcing material along sharf to, from blade root portion to the blade tip end by stepped arrangement.
5, large pneumatic equipment blades made of composite material according to claim 1 is characterized in that:
Described keel frame is discontinuous, by being formed by connecting from beginning to end piecemeal.
6, large pneumatic equipment blades made of composite material according to claim 1 is characterized in that:
The connection blade connects firmly with the keel frame more than a section or a section that leans on root of blade to the connection piece of wind energy conversion system main drive shaft.
7, large pneumatic equipment blades made of composite material according to claim 1 or 5 is characterized in that:
Described keel frame is a hollow structure, is made by short fiber reinforced composite.
8, according to claim 5 or 7 described large pneumatic equipment blades made of composite material, it is characterized in that:
Described keel frame is a hollow structure, through injection molding machine shaping.
9, according to claim 1 or 7 or 8 described large pneumatic equipment blades made of composite material, it is characterized in that:
The keel frame is a hollow structure, is made by plank or wooden splint, batten.
10, a kind of large pneumatic equipment blades made of composite material preparation method is characterized in that:
Get through the forming die preparation by cloth of reinforcement fibers, resin base, keel frame, link, latex bonded fibre cloth is sprawled by stepped in lower mode cavity, put the keel frame of end-to-end, wherein link is fixed with the keel frame of holding by blade root, sprawl successively again with lower mode cavity in the fibre cloth of each layer latex bonded fibre cloth symmetry, each fibre cloth periphery is sewed up, close up up and down die cavity, seal, vacuumize, injecting resin, intensification solidify, slough die cavity, obtain wind machine's laminae made from composite material.
CNB2005100234880A 2005-01-21 2005-01-21 Large pneumatic equipment blades made of composite material and production thereof Expired - Fee Related CN100385113C (en)

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CN104943202A (en) * 2015-07-03 2015-09-30 浙江大学 Carbon fiber composite material axial flow fan impeller molding and curing device
CN107859591A (en) * 2017-09-29 2018-03-30 上海玻璃钢研究院东台有限公司 A kind of wind electricity blade and preparation method thereof
CN109514885A (en) * 2018-11-29 2019-03-26 洛阳双瑞风电叶片有限公司 A kind of etch-proof wind electricity blade of leading edge and its forming method

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US8402652B2 (en) 2005-10-28 2013-03-26 General Electric Company Methods of making wind turbine rotor blades
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CN100412356C (en) * 2006-08-31 2008-08-20 东莞中德风电能源有限公司 Blades of wind energy generator and manufacturing method
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