CN1954995A - 风涡轮转子叶片的制造方法 - Google Patents

风涡轮转子叶片的制造方法 Download PDF

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CN1954995A
CN1954995A CNA2006101428784A CN200610142878A CN1954995A CN 1954995 A CN1954995 A CN 1954995A CN A2006101428784 A CNA2006101428784 A CN A2006101428784A CN 200610142878 A CN200610142878 A CN 200610142878A CN 1954995 A CN1954995 A CN 1954995A
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resin
core body
microporous barrier
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fibre
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J·W·巴克惠斯
A·比伦
S·范布罗伊格尔
J·利文斯顿
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General Electric Co
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    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
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    • F03D1/0675—Rotors characterised by their construction elements of the blades
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082—Blades, e.g. for helicopters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • F05B2280/00—Materials; Properties thereof
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract

一种制造风涡轮转子叶片(114)的方法，在一个实施例中，包括以下步骤：提供一个芯体(120)，在该芯体上敷设至少一层增强表层(126)从而形成一个叶片子组件(131)。增强表层各由一层增强纤维构成。该方法还包括：敷设一层微孔膜(128)包覆该至少一层增强表层，敷设一层真空膜，包覆该微孔膜，将聚合物树脂引入到芯体上，在该叶片子组件内造成真空，灌注树脂使它通过该芯体和该至少一层增强表层，及使树脂硬化从而形成转子叶片。

Description

风涡轮转子叶片的制造方法
技术领域
本发明总的涉及风涡轮，尤其涉及利用微孔膜制造风涡轮转子叶片的方法。
背景技术
近来，风涡轮作为环境安全、费用较省的可替代能源日益受到人们的注意。由于增长的关注，人们曾作相当大的努力来研发可靠而有效的风涡轮。
一般来说，风涡轮包括一个具有多个叶片的转子。该转子装在一个位于桁架或管塔顶部的壳体或机舱上。公用类的转子(即用来供电到公用电网的风涡轮)能具有巨大的转子(例如直径为30米或以上)。转子上的叶片将风能转变为转矩或力以此来驱动通过齿轮箱可旋转地联接到转子上或直接联接到转子上的一台或多台发电机。该齿轮箱如果存在，可将涡轮转子原有的低转速提高后供给发电机以便有效地将机械能转变为馈送到公用电网内的电能。
已知的风涡轮叶片是用树脂灌注到纤维包扎的芯体内制成的。其时使用一层分配筛来将树脂输送到芯体材料内。通过在该分配筛内的破裂来控制注入流体的前沿，该分配筛需要准确的定位以便得到所需的结果。而且，该分配筛是连同被留在该筛内的每平方米约650克的树脂被舍弃的。
本发明概述
本发明的一个方面提供的制造风涡轮转子叶片的方法，包括提供一个芯体并在其上敷设至少一层增强表层以便形成叶片子组件的步骤。增强表层都由增强纤维层构成。该方法还包括敷设一层微孔膜包覆该至少一层增强表层，敷设一层真空膜包覆该微孔膜，将聚合物树脂引到芯体上，在叶片组合件上造成真空使树脂灌注透过该芯体并透过该至少一层增强表层，及使树脂硬化而形成转子叶片。
本发明的另一个方面提供的制造风涡轮转子叶片的方法，该方法包括提供一个芯体并在其上敷设至少一层增强表层以便形成叶片子组件，并将该叶片子组件定位于模中的步骤。增强表层都由增强纤维层构成。该方法还包括敷设一层微孔膜包覆该至少一层增强表层，敷设一层真空膜包覆该微孔膜，将聚合物树脂引到芯体上，在叶片组合件上造成真空使树脂灌注透过该芯体并透过该至少一层增强表层，及使树脂硬化而形成转子叶片。
附图的简要说明
图1为一风涡轮示例性结构的简略侧视图。
图2为图1中所示风涡轮转子叶片的简略侧视图。
本发明的详细说明
下面详述利用微孔膜制造风涡轮转子叶片的方法。微孔膜阻止树脂通过但允许气体通过。这样便可在整个转子叶片上造成真空而不是像在已知的方法中那样仅在周边上造成真空。微孔膜还可便于控制液流前沿并消除树脂流的任何尾迹。制造周期和工时都可减少，连同减少的还有制造过程中消耗材料的费用。使用微孔膜还可提高叶片质量，例如，较低的空隙含量和优化的增强纤维对树脂的比率。
参阅附图，图1为一具有水平轴线的风涡轮100的侧立面略图。该风涡轮100包括一个从支承表面104升起的塔102、一个装在塔102的座架108上的机舱106、和一个联接到机舱106上的转子110。转子110包括一个毂部112和多个联接到毂部112上的叶片114。在该示例性实施例中，转子110包括三个转子叶片114。在一可替代的实施例中，转子110包括多于或少于三个转子叶片114。在该示例性实施例中，塔102由钢管制成并包括一个在支承表面104和机舱106之间延伸的空腔。在一可替代的实施例中，塔102为一格构塔。
在该示例性实施例中，风涡轮100的各个构件被容纳在风涡轮100塔顶102的机舱106内。塔102的高度根据本行业所知的各种因素和条件来选定。在有些设计中，在控制系统中有一个或多个微控制器被用来作为整个系统的监视和控制包括倾斜和速率的调整、高速轴和偏转制动器的应用、偏转和泵电动机的应用、及事故监控。在风涡轮100的另外一些实施例中使用可替代的分散或集中的控制结构。在该示例性实施例中，叶片114的倾角(pitch)是被个别控制的。毂部112和叶片114一同被固定在风涡轮的转子110上。转子112的旋转使发电机(图上未示出)产生电力。
使用时，叶片114被定位于转子毂部的周围以便转动转子110将来自风的动能转变为可用的机械能。当风冲击叶片114并且当叶片114被转动而受到离心力时，叶片114受到各种弯曲力矩。这样，叶片114就会偏斜及/或从一个中间的或不偏斜的位置旋转到偏斜的位置。另外，叶片114的俯仰角能被俯仰机构(未示出)改变以便增加或减少叶片114的速率，并且以便减少塔102所受冲击。
参阅图2，叶片114包括一个由聚合物泡沫材料、木材及/或金属蜂窝格栅构成的芯体120。有一主椽子122和一端椽子124被埋在芯体120内。合适的聚合物泡沫材料例如包括但并不限于，聚氯乙烯、聚烯烃、环氧树脂、聚氨酯、聚异氰脲酸酯等泡沫材料和其混合物。芯体120被至少一层增强表层126包裹。增强表层126各由一层增强纤维构成，可以是织造的或非织造的。合适的增强纤维例如包括但并不限于，玻璃纤维、石墨纤维、碳纤维、聚合物纤维、陶瓷纤维、芳族聚酰胺纤维、洋麻纤维、黄麻纤维、亚麻纤维、大麻纤维、纤维素纤维、剑麻纤维、椰纤维、和其混合物。
树脂被灌注到芯体120和增强表层126内以便给叶片114提供整体性和强度。合适的树脂例如包括但并不限于，乙烯基酯树脂、环氧树脂、聚酯树脂、和其混合物。有一微孔膜128被敷设到叶片114的外表面上以便进行树脂灌注过程。树脂在真空下被引入到芯体120内。真空使树脂流动通过芯体120和增强表层126。微孔膜128允许被树脂驱赶的空气从芯体120和增强表层126中逸出。但微孔膜128不允许树脂通过膜128流出。在一个示例性实施例中，微孔膜上孔的平均大小约为0.01微米(μ)到约10μ，而在另一个实施例中则为0.1μ到约5。微孔膜128例如可由聚四氟乙烯、聚烯烃、聚酰胺、聚酯、聚砜、聚醚、丙烯酸和甲基丙烯酸聚合物、聚苯乙烯、聚氨酯、聚丙烯、聚乙烯、聚亚苯基砜(polyphenelene)和其混合物构成。在有一个实施例中，微孔膜128还包括一个层压到一表面上的衬垫材料。该衬垫材料系由聚合物纤维，例如聚酯纤维、尼龙纤维、聚乙烯纤维、和其混合物构成。有一层空气输送材料129位于微孔膜128之上，允许被灌注树脂驱赶的空气逸出到大气中，用来协助芯体除气。空气输送材料可由任何合适的网格材料例如聚乙烯网构成。
在该示例性实施例中，芯体120包括多条沟槽130以便树脂流动通过芯体120。在另外一些实施例中，芯体120则不包括沟槽130。
为了形成转子叶片114，增强表层126被包裹在芯体120的周围形成一个叶片子组件131，然后被定位于一模型132内。而在另外一些实施例中则没有使用模型132。有一树脂灌注输入连管134被定位于外增强表层126的邻近。然后将微孔膜128定位于外增强表层126和树脂灌注输入连管之上。再把空气输送材料129定位于微孔膜128之上，并将一个真空连管定位于空气输送材料129的邻近。有一用合适材料，例如聚酰胺制成的真空膜138被定位于空气输送材料129之上，其时真空连管136通过真空膜138伸出。当通过真空连管136建立起真空时，树脂就通过输入连管134被引入到芯体120和增强表层126内。真空使树脂容易流动并灌注到芯体120和增强表层126内。微孔膜128阻止树脂从芯体120和增强表层126内向外流出，同时允许被灌注树脂驱赶的空气逸出到大气中。树脂然后被硬化，而树脂输入连管134、真空连管136、空气输送材料129、和真空膜138随后都被从叶片114上撤走。
虽然本发明已用各个具体实施例说明，本行业的行家将会认识到，在权利要求书限定的精神和范围内实施本发明是可以作出各种修改的。

Claims (10)

1.一种制造风涡轮(100)转子叶片(114)的方法，包括：
提供一个芯体(120)；
将至少一层增强表层(126)敷设到该芯体上，各增强表层由一增强纤维垫构成，从而形成一个叶片子组件(131)；
将一层微孔膜(128)敷设在该至少一层增强表层上；
将一真空膜(138)敷设在该微孔膜上；
将聚合物树脂引入到该芯体上；
通过对该叶片子组件施以真空经该芯体和该至少一层增强表层灌入该树脂；及
使该树脂硬化以形成该转子叶片。
2.权利要求1的方法，其特征在于，提供一个芯体(120)，包括提供一个具有多条沟槽(130)的芯体以允许该树脂流过该芯体的步骤。
3.权利要求1的方法，其特征在于，该增强纤维包括下列各材料中的至少一种：玻璃纤维、石墨纤维、碳纤维、陶瓷纤维、芳族聚酰胺纤维、洋麻纤维、黄麻纤维、亚麻纤维、大麻纤维、纤维素纤维、剑麻纤维和柳纤维。
4.权利要求1的方法，其特征在于，还包括在真空膜(138)和微孔膜(128)之间敷设一空气输送材料层(129)。
5.权利要求1的方法，其特征在于，该树脂包括乙烯基酯树脂、环氧树脂和聚酯树脂中的至少一种。
6.权利要求1的方法，其特征在于，芯体(120)包括聚合物泡沫材料、木材和金属蜂窝中的至少一种。
7.权利要求1的方法，其特征在于，微孔膜(128)包括下列各材料中的至少一种：聚四氟乙烯、聚烯烃、聚酰胺、聚酯、聚砜、聚醚、丙烯酸和甲基丙烯酸的聚合物、聚苯乙烯、聚氨酯、聚丙烯、聚乙烯和聚亚苯基砜。
8.权利要求1的方法，其特征在于，微孔膜(128)具有多个微孔，其平均直径约从0.01μ到约10μ。
9.权利要求1的方法，其特征在于，微孔膜(128)具有多个微孔，其平均直径约从0.1μ到约10μ。
10.权利要求1的方法，其特征在于，该微孔膜(128)在一个表面上具有一层衬垫材料。
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