CN1915649B - 可用于制造转子叶片圆柱盖的一种制造连续层压片的方法 - Google Patents

可用于制造转子叶片圆柱盖的一种制造连续层压片的方法 Download PDF

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CN1915649B
CN1915649B CN2006101262346A CN200610126234A CN1915649B CN 1915649 B CN1915649 B CN 1915649B CN 2006101262346 A CN2006101262346 A CN 2006101262346A CN 200610126234 A CN200610126234 A CN 200610126234A CN 1915649 B CN1915649 B CN 1915649B
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R·阿雷尔特
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Abstract

一种制造连续层压片的方法，尤其适合于风能涡轮转子叶片的圆柱盖或其他部件，所述方法包括步骤：提供多个平行的纤维(12)；将所述纤维(12)嵌入可固化的基体材料(16)；固化所述基体材料(16)，得到具有上和下主表面(28，30)的纤维增强的层压片(20)；和在所述层压片(20)的上和下主表面(28，30)其中至少一个形成沟槽(32，34)，其中所述上和/或下主表面(28，30)的沟槽(32，34)倾斜于纤维(12)的方向。

Description

可用于制造转子叶片圆柱盖的一种制造连续层压片的方法
技术领域
本发明涉及一种制造纤维增强的环状或连续层压片的方法，适用于制造风能涡轮机转子叶片的圆柱盖或其他部分。此外，本发明涉及使用层压片制造结构件，如风能涡轮转子叶片的圆柱盖或其他部件。
背景技术
已知道连续层压片，即纤维增强的树脂或其他可固化材料的环形平板。通过拉动纤维(如玻璃或碳纤维)束通过树脂槽，形成平板，经连续工艺过程生产出这些层压片。层压片中的纤维并排放置，基本互相平行对齐。这些连续层压片的厚度在不到1毫米至数毫米之间。层压片的宽度基本可以具有各种尺寸。基体材料(如树脂)在循环工艺中固化。片状层压片缠绕成卷，长度为二百米。这些层压片适合于叠置成部分或层，用于如风能涡轮叶片的圆柱盖。当纤维基本上完美对齐，并在预制层压片内保持对齐时，可使得制造叶片时模具中层压片的各层纤维不对齐(碳纤维对不对齐非常敏感)的问题减少。
上面介绍的连续纤维增强层压片可从芬兰公司EXEL购买。
使用连续预制的纤维增强层压片制造风能涡轮转子叶片的圆柱盖或其他部件涉及一种设置，其中多层的层压片切割件须一层置于一层上，以形成结构件。这些结构件设置在转子叶片模具的特定区域和部分，模具中还设置其他夹层构件。转子叶片的圆柱盖和其他夹层结构件形成刚性的和抗剪的整体结构件，其重量轻并且非常稳定。为了制造这样的叶片，使用了熔浸工艺，在进行熔浸时可固化的材料(如树脂)流入模具中，以便渗透到层压片的各层之间，以及层压片与转子叶片的结构件之间。在熔浸工艺期间，真空施加到模具，使层压片的各层压接一起。熔浸工艺还可用于制造层压片的其他部件。在熔浸工艺期间，可能发生可固化的材料流入模具但未渗透层压片各层之间。这样熔浸工艺将导致层压片相邻层形成不足够的机械连接，因此使得纤维增强层压片制成的转子叶片或其他部件的结构刚性和稳定性不够。
发明内容
通过一种制造连续层压片的方法解决了上面提到的问题，该方法尤其适合于制造风能涡轮转子叶片的圆柱盖或其他部件，该方法包括步骤：
提供多个平行纤维；
将纤维嵌入可固化的基体材料；
固化基体材料，得到具有上和下主表面的纤维增强层压片；和
在层压片的上和下主表面其中至少一个表面形成沟槽，其中上和/或下主表面的沟槽相对纤维的方向倾斜。
因此，通过本发明的方法，连续纤维增强的连续层压片的至少一个表面制备好，以便设置沟槽，供熔浸工艺期间可固化材料(如树脂)在形成叠层的连续层压片的各层之间移动。本发明的目的是使得在连续层压片的叠层的相邻层之间甚至在高压下都有调整好的空隙，该目标的实现是通过在连续层压片初步制造和固化后，或与其同时，在连续层压片的至少一个表面形成沟槽。
在本发明的一个方面，使用磨削工具磨削纤维增强连续层压片，在至少一个主表面形成沟槽。磨削工具横向于纤维增强连续层压片的纤维并横向于纤维增强连续层压片的生产工艺的方向进行移动。这样通过磨削连续层压片的上和下主表面其中至少一个的部分材料形成横向槽。因此，将纤维切至磨削切口的深度。切掉的纤维应当从连续层压片的承受载荷截面区减去。通过调节连续层压片和磨削工具的移动速度，可调节沟槽相对连续层压片的主要路径(纵向)的角度。沟槽最好是在连续层压片的两个主表面形成。上和下主表面的沟槽角度互不相同，或是从正角度转变为负角度，以保证沟槽互相相交，使得连续层压片的上和下主表面的沟槽在叠放多个连续层压片时不会配对和互相靠近。磨削工具或其他沟槽形成工具的粗糙度应当进行调节，以满足在层之间移动的可固化材料(如树脂)的要求，并减少熔浸工艺期间进入的可固化材料的流动阻力。
根据本发明的另一方面，连续层压片的基体材料固化的同时在连续层压片的上和/或下主表面上形成沟槽。在这个过程中，沟槽最好不在连续层压片的设有纤维的厚度区内形成。因此，连续层压片包括上和/或下厚度部分，其中形成沟槽，和设置在上下部分之间的中间部分，其中设置纤维。
权利要求的主题涉及到了本发明的其他实施例和方面。
附图说明
下面将参考附图更详细地介绍本发明。附图中：
图1示意性地显示了根据本发明的用于制造纤维增强连续层压片的方法的第一实施例的各工艺步骤；
图2显示了根据图1示意性显示的工艺制造的层压片的切割部分的透视图；
图3显示了图2的圆区域III的切割部分放大图；
图4示意性地显示了根据本发明的第二实施例的制造纤维增强连续层压片的方法的第一实施例的各个工艺步骤；
图5显示了转子叶片的截面图，包括通过互相叠放的连续层压片叠层所形成的圆柱盖和其他部件。
具体实施方式
图1显示了制造纤维增强连续层压片10的方法的第一实施例的各步骤。从卷绕14拉出多个基本上平行的玻璃或碳纤维12，使其通过环氧树脂槽16。但是也可使用其他的纤维12可浸入的可固化材料。
浸入环氧树脂的纤维12的部分传输到凝固工位18。然后，固化的层压片20又输送到沟槽形成工位22，其设有两个磨削工具24，26，可用来磨削固化的层压片20的上和下主表面。在沟槽形成工位22，通过上和下磨削工具24，26，在固化的层压片20的上和下主表面28，30形成各沟槽32，34，以便形成最后的预制连续纤维增强的层压片10，层压片然后卷绕成卷筒36。从卷筒36可切割出多个单独的层压片部分(也称作平板)，可以互相层叠制成纤维增强的层压件。
在沟槽形成工位22，通过磨削在固化的层压片20的主表面形成沟槽32，34。各主表面上的沟槽基本是互相平行的，各组基本平行的沟槽32，34相互倾斜，并相对连续层压片10的纵向倾斜。在连续层压片10的两个主表面28，30上的沟槽32，34可具有不同的尺寸。例如，下主表面30的沟槽34的截面积小于连续层压片10的上主表面28的沟槽32的截面积。
图2显示了连续层压片10的切割部分，显示出纤维层12，以及相互倾斜的各组沟槽32，34，沟槽相对连续层压片10的纵向倾斜。另外，还可看到沟槽32，34在上和下主表面28，30切割出，纤维12设置在层压片切割区之间。
沟槽32，34还可通过在制造连续层压片的过程中施加外壳件来形成，外壳件在固化后取下。可选择外壳件的结构，使得连续层压片能形成希望的表面状态。
图4显示了另一个制造连续层压片10的工艺。图4所显示的层压片与图1和2所示的相同或类似，采用了相同的标记。
多个玻璃或碳纤维12从卷绕14拉出，并通过可固化材料(如环氧树脂)槽16。纤维12嵌入其中的树脂部分传输到固化和沟槽形成工位18，22，使这部分固化并在上和下主表面28，30形成沟槽32，34。在固化和沟槽形成工位，分别具有各自模具42，44的上和下链条38，40分别设置在部分10的上和下方，以便在未固化的组分的上和下部46，48形成沟槽32，34，组分中嵌入纤维12。制造出的连续层压片10又再缠绕成卷36。
图5显示了风能涡轮叶片50，其包括形成叶片50壳体的上和下壳体52，54。叶片50的壳体包括上和下夹层结构56，58和60，62，其间设有圆柱64。夹层结构56，58和60，62分别包括刚性的外壳66，68，其间是间隔件70(仅见于图5的层压件56)。外壳66，68可包括纤维增强树脂，间隔件70可包括夹层结构，泡沫或重量轻的材料，如木棉。这些夹层结构对于制造转子叶片都是公知的。
圆柱64包括上圆柱盖72和下圆柱盖74，以及其间的两个抗剪肋。抗剪肋76还包括夹层结构，如前面所介绍的。圆柱盖72，74以及前端和后端78，80都用层压片10的叠层制造，层压片叠层件通过图1到3所介绍的表面沟槽制造和提供。
具有各夹层结构和层压件部分的图5所示的叶片50的整体结构基本上已知道。但是，根据本发明，图5所示的叶片50包括层压结构件，层压结构件由根据图1到3制造的连续层压片10的部件形成。这些层压结构件，由于在层压片各层上存在沟槽32，34，制造叶片50的熔浸工艺期间所提供的树脂或类似可固化的材料可浸入沟槽，树脂或可固化的材料可完全和均匀地在相邻层之间分布，使得层压片的相邻层之间形成理想的连接。
尽管已经参考特定显示的实施例对本发明进行了介绍，但不希望本发明限于这些示例性的实施例。例如，连续层压片的主表面中至少一个上的沟槽可以是弯曲的和相交。粗糙的连续层压片可提供层压片的相邻层之间的槽状空间。所属领域的技术人员应认识到可进行各种变化和改进，这些未脱离所附权利要求限定的本发明的真实范围。因此希望当其落入所附权利要求和等效体的范围内时，本发明的范围包括这些变化和改进。

Claims (10)

1.一种制造连续层压片的方法，所述方法包括步骤：
在一个方向上提供多个平行的纤维；
将所述纤维嵌入可固化的基体材料；
固化所述基体材料，得到具有上和下主表面的纤维增强层压片；和
在所述层压片的上和下主表面中至少一个表面中磨削去预定深度的材料并将纤维切至所述预定深度以形成沟槽，其中所述沟槽相对纤维的方向倾斜。
2.根据权利要求1所述的方法，其特征在于，所述沟槽在上和下两个主表面上形成，其中上主表面上的沟槽相对下主表面上的沟槽倾斜。
3.根据权利要求2所述的方法，其特征在于，上主表面上的沟槽和下主表面上的沟槽具有不同的尺寸。
4.根据权利要求1所述的方法，其特征在于，使用至少一个磨削工具进行切割。
5.根据权利要求1所述的方法，其特征在于，在基体材料进行固化的同时，在上和/或下主表面上形成沟槽。
6.根据权利要求1所述的方法，其特征在于，纤维可选择玻璃或碳纤维中的至少一种。
7.根据权利要求1所述的方法，其特征在于，所述基体材料是树脂。
8.根据权利要求7所述的方法，其特征在于，所述基体材料是环氧树脂。
9.根据权利要求1所述的方法，其特征在于，位于一个主表面的沟槽基本互相平行。
10.根据权利要求1所述的方法，其特征在于，所述沟槽延伸到层压片的边缘。
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