JP2016032929A - Method for producing thermoplastic resin molding and windmill blade, and thermoplastic resin molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate recycling of a waste material, and have a short manufacturing step.SOLUTION: In a method for producing a windmill blade, a laminated body S in which a plurality of thermoplastic resin sheets 11 are laminated between a plurality of fiber-reinforced resin sheets 12 formed by impregnating a carbon fiber with a thermosetting resin is bent along an inner surface of a mold 7 and placed. A back side half body 1a is produced by heating the laminated body S through the mold 7 to high temperature, and heating and melting the fiber-reinforced resin sheets 12 and the thermoplastic resin sheets 11 to be integrated with each other. At the time of heating, each of the sheets 11 and 12 is brought into close contact with each other by vacuuming air from each of the end faces and the bottom faces of the plurality of the fiber-reinforced resin sheets 12 and the thermoplastic resin sheets 11 with a suction pipe 9. After heating, the mold 7 is cooled and the back side half body 1a is taken out, and the taken back side half body 1a is joined to an abdominal side half body which has been similarly produced, and a windmill blade is formed. In the windmill blade, a thermoplastic resin layer 3 of the thermoplastic resin sheet 11 is laminated between a fiber-reinforced outer layer 4 and a fiber-reinforced inner layer 5 which are formed of the fiber-reinforced resin sheet 12.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a method for producing a thermoplastic resin molded body such as a windmill blade used for wind power generation, a windmill blade, and a thermoplastic resin molded body.

Conventionally, wind turbine blades used for wind power generation are required to have high strength, light weight, and durability. In particular, wind turbine blades, aircraft and ship bodies are made of large fiber-resin composites and are usually manufactured using thermosetting resins. Strengthening is important. For example, in the wind turbine blade 100 described in Patent Document 1, a spar cap 102 is disposed as a spine portion and an abdominal portion in a streamlined outer skin layer 101 having a predetermined thickness as shown in FIG. A sandwich core material 103 made of lightweight wood is incorporated in the interior. In addition, the dorsal and ventral spar caps are connected and supported by the share web 104.
The outer skin layer 101 of the wind turbine blade 100 is manufactured by pouring a liquid thermosetting resin into a fiber base material and curing it by heating.

That is, the outer skin layer 101 is impregnated with a liquid thermosetting resin (such as an unsaturated polyester) by a vacuum suction method in a dry fabric (glass fiber fabric) arranged along a mold, and then cured by heating. Thus, a method of manufacturing a half body of a wind turbine blade that integrates the outer skin layer 101 including the spar cap 102 and the sandwich core material 103 is described. And the windmill blade is formed by joining one manufactured half body and the other half body with an adhesive agent.
Moreover, not only wind turbine blades, but also large fiber resin composite molded bodies such as aircraft and ship bodies and building flooring are all thermoset with dry fabric (glass fiber fabric) placed in the mold. It is manufactured by pouring the mold resin under vacuum and impregnating it, followed by heat curing.

JP 2009-287514 A

  However, a large-sized fiber resin composite molded body such as a wind turbine blade described in Patent Document 1 is formed by pouring a liquid thermosetting resin into a fiber base material. Recycling was difficult when discarded. In addition, there is a problem that it takes time to inject and impregnate the thermosetting resin into the fiber base material, and it takes a long time to cure, resulting in a long manufacturing cycle.

  The present invention has been made in view of such a problem, and a method for manufacturing a thermoplastic resin molded body that allows easy recycling of waste and a short manufacturing process, and a windmill made of this thermoplastic resin molded body. It aims at providing a wing | blade and a thermoplastic resin molding.

The method for producing a thermoplastic resin molded body according to the present invention includes a step of placing a plurality of thermoplastic resin sheets in a mold and laminating them, and heating the laminated thermoplastic resin sheets to form the thermoplastic resin sheet. And a step of forming the thermoplastic resin sheet formed after cooling from a mold, and a step of taking out the molded body of the integrated thermoplastic resin sheet after cooling.
According to the present invention, it is possible to manufacture a thermoplastic resin molded body by heating a plurality of thermoplastic resin sheets laminated in a mold, heat-welding each other, and cooling by integration. The manufacturing process can be reduced because the process is short, and the weight can be reduced as compared with the conventional thermosetting resin molding. Further, when the thermoplastic resin molded body is discarded, it can be crushed and extruded to be recycled to other resin products.

Moreover, it is preferable to laminate | stack the reinforced fiber resin sheet containing the reinforced fiber and thermoplastic resin stronger than a thermoplastic resin sheet to one or both of the front and back of a some thermoplastic resin sheet.
A thermoplastic fiber sheet is laminated on one or both of the front and back surfaces of a thermoplastic resin sheet and heated and melted together to form a thermoplastic resin molded product. Therefore, the manufacturing process is short and high strength and rigidity are high. The physical properties equivalent to those of conventional thermosetting resin moldings can be obtained.

Moreover, you may make it heat the laminated | stacked thermoplastic resin sheet and a reinforced fiber resin sheet by raising the temperature of a metal mold | die.
The thermoplastic resin sheet and the reinforcing fiber resin sheet can be melted and integrated by heating the mold.

Moreover, after laminating a plurality of thermoplastic resin sheets and reinforcing fiber resin sheets in a mold, air may be discharged from the end portions of the plurality of thermoplastic resin sheets and reinforcing fiber resin sheets.
By discharging the air between the sheets from the end portions of the plurality of thermoplastic resin sheets and reinforcing fiber resin sheets, integration by melting the thermoplastic resin sheets can be promoted.

The reinforcing fiber contained in the reinforcing fiber resin sheet is carbon fiber, glass fiber, or high-strength organic fiber.
By impregnating a thermosetting resin using carbon fiber, glass fiber, or high-strength organic fiber as the reinforcing fiber, the strength and rigidity of the thermoplastic resin molded body can be improved.

A thermoplastic resin molded body may be manufactured by joining a plurality of thermoplastic resin molded bodies manufactured by any one of the methods for manufacturing a thermoplastic resin molded body described above.
By joining a plurality of thermoplastic resin moldings to each other, an integral thermoplastic resin molding can be manufactured as a whole.

The wind turbine blade according to the present invention is characterized in that a reinforcing fiber resin layer containing a reinforcing fiber and a thermoplastic resin having higher strength than the thermoplastic resin layer is laminated and integrated on the surface of the thermoplastic resin layer.
According to the present invention, the wind turbine blade obtained by laminating and integrating the thermoplastic resin layer and the reinforcing fiber resin layer can be reduced in weight as compared with the conventional thermosetting resin molded body, and the rigidity is equivalent. When the wind turbine blades are discarded, they can be crushed and extruded to be recycled into other resin products. The reinforcing fiber resin layer may be laminated and integrated on at least one of the front and back surfaces of the thermoplastic resin layer.

Moreover, you may form a part of thermoplastic resin layer or a reinforced fiber resin layer thicker than another area | region.
Thereby, the strength of the thick portion of the wind turbine blade can be set higher.

Further, the method for producing a thermoplastic resin molded body according to the present invention includes a step of placing a plurality of thermoplastic resin sheets and a reinforced fiber resin sheet to form a laminate, and a plurality of thermoplastic resins by heating the laminate. The process of melting and integrating the sheet and the reinforcing fiber resin sheet with each other, and compressing the laminated body with a pair of molds, allows the molten thermoplastic resin to flow, and part of the molded body from other regions You may make it provide the process of forming in thickness, and the process of taking out the molded object integrated after cooling from a metal mold | die.
Further, the thermoplastic resin molded body according to the present invention includes a thermoplastic resin layer that is thicker than other regions in part using the method for manufacturing a thermoplastic resin molded body, and is provided on the surface side of the thermoplastic resin layer. It may be formed with a reinforcing fiber resin layer containing reinforcing fibers and a thermoplastic resin.
According to these inventions, at a stage where a laminated body constituted by placing a plurality of thermoplastic resin sheets and reinforcing fiber resin sheets is heated and melted and integrated with each other, a desired uneven shape (inclined shape) is obtained. The laminate is compressed with a mold having a curved surface shape, etc.), and the molten thermoplastic resin is caused to flow, and a part of the molten thermoplastic resin is caused to flow according to the shape of the mold surface. It becomes possible to make it thicker than other regions. That is, by using the thermoplastic resin in this way and pressing and flowing the thermoplastic resin that has been heated and melted with a mold, it becomes possible to easily produce a molded body having a desired uneven shape. .
In addition, examples of the structure (molded body) having a thick part thicker than other regions include a skin-rib structure.

According to the method for manufacturing a thermoplastic resin molded body according to the present invention, a thermoplastic resin molded body can be manufactured by heating, melting, integrating, and cooling a plurality of thermoplastic resin sheets laminated in a mold. Therefore, the weight can be reduced as compared with the conventional thermosetting resin molded body, and the manufacturing process is shortened, so that an increase in manufacturing cost can be suppressed.
In addition, when the thermoplastic resin molding is discarded, it can be pulverized and extruded, so that it can be recycled to other resin products.

  Further, according to the wind turbine blade according to the present invention, the thermoplastic resin layer and the reinforced fiber resin layer are laminated and integrated, so that the weight can be reduced as compared with the wind turbine blade of the conventional thermosetting resin molded body. The rigidity is equivalent and can be recycled to other resin products when discarded.

It is a schematic longitudinal cross-sectional view of the windmill blade by 1st embodiment of this invention. It is a disassembled perspective view of the laminated body formed by laminating | stacking the thermoplastic resin sheet by 1st embodiment, and the upper and lower reinforcement fiber resin sheet. It is a figure which shows the manufacturing method of the windmill blade by this embodiment, (a) is sectional drawing which shows the metal mold | die of the half body of a windmill blade, (b) is a thermoplastic resin sheet and a reinforced fiber resin sheet in a metal mold | die. Sectional drawing which mounted the laminated body, (c) is sectional drawing which heated the laminated body and formed the half body of the windmill blade. It is A section sectional drawing in FIG.3 (b). It is a B section sectional view in Drawing 3 (c). It is sectional drawing which shows the process of heat-joining one half body and the other half body of a windmill blade. It is a disassembled perspective view of the laminated body formed by laminating | stacking the thermoplastic resin sheet by 2nd embodiment of this invention, and the upper and lower reinforcement fiber resin sheet. It is sectional drawing of the state which mounted the laminated body of the thermoplastic resin sheet by 2nd embodiment, and the upper and lower reinforcement fiber resin sheet in the metal mold | die. It is sectional drawing of the half body of the windmill blade by which the interlayer of the thermoplastic resin sheet shown in FIG. 8 and the upper and lower reinforcement fiber resin sheets was joined. It is a figure which shows the relationship between the displacement and rigidity of the Example of this invention, and a prior art example. It is sectional drawing which shows the manufacturing method of the thermoplastic resin molding by 3rd embodiment of this invention, and the thermoplastic resin molding manufactured using this manufacturing method. It is a longitudinal cross-sectional view which shows the conventional windmill blade.

Hereinafter, a huge wind turbine blade that is a thermoplastic resin molded body according to an embodiment of the present invention and a method for manufacturing the same will be described with reference to the accompanying drawings.
FIG. 1 is a longitudinal sectional view of a wind turbine blade 1 which is a thermoplastic resin molded body according to a first embodiment of the present invention. In the wind turbine blade 1 shown in FIG. 1, an outer skin layer 2 made of a thermoplastic resin is formed in a streamline shape, for example. The three layers constituting the outer skin layer 2 are integrally formed by laminating a thick thermoplastic resin layer 3 and a thin reinforcing fiber outer layer 4 and a reinforcing fiber inner layer 5 laminated on the outer surface side and the inner surface side thereof. Has been. The reinforcing fiber outer layer 4 and the reinforcing fiber inner layer 5 are constituted by thin layers in which a carbon fiber is impregnated with a thermoplastic resin.

  In addition, the wind turbine blade 1 shown in FIG. 1 has end faces 2a and 2b of the dorsal half body 1a having a substantially arc shape in the upper cross section, which is the outer skin layer 2, and the ventral half body 1b having a substantially arc shape in the lower cross section. It is formed by bonding. In the wind turbine blade 1 according to the present embodiment, a share web is not installed between the back half body 1a and the abdomen half body 1b. However, in order to reinforce the wind turbine blade 1, a share web or the like is installed between the half bodies 1a and 1b. You may connect.

Next, the manufacturing method of the huge windmill blade 1 by this embodiment is demonstrated with reference to FIGS.
In the fiber composite shown in FIG. 2, a plurality of reinforcing fiber resin sheets 12 that form the reinforcing fiber outer layer 4 are arranged on a plane and arranged, and the width of the single reinforcing fiber resin sheet 12 is the inner surface of the mold 7. For example, it corresponds to a length of 1/3 of 7a. The reinforcing fiber resin sheet 12 is, for example, a sheet-like prepreg in which a woven carbon fiber is impregnated with a thermoplastic resin.
On the reinforced fiber resin sheet 12, the necessary number of thermoplastic resin sheets 11 for forming the thermoplastic resin layer 3 are stacked and placed. Further, a necessary number of reinforcing fiber resin sheets 12 forming the reinforcing fiber inner layer 5 are stacked and placed on the thermoplastic resin sheet 11. These constitute the laminated body S.

The metal mold 7 shown in FIG. 3A has an inner surface 7 a having a shape that forms, for example, the back half body 1 a of the wind turbine blade 1. And in the vicinity of the inner surface 7a in the mold 7, temperature adjusting means including a temperature adjusting pipe 8 for selectively passing high-temperature steam and cooling water, and vacuum suction of the reinforcing fiber resin sheet 12 on the inner surface 7a A suction means including a suction pipe 9 is provided. Note that the configurations and arrangements of the temperature adjustment pipe 8 and the suction pipe 9 are exemplary, and an arbitrary configuration of temperature adjustment means and suction means can be employed as necessary.
And as shown in FIG.3 (b), on the inner surface 7a of the metal mold | die 7, the laminated body S which consists of the thermoplastic resin sheet 11 and the upper and lower reinforcement fiber resin sheets 12 curved along the shape of the inner surface 7a. It is placed in shape.

Here, prior to the description of the method of manufacturing the wind turbine blade 1, the configuration of each layer shown in FIG. 4 will be described.
The thermoplastic resin sheet 11 has a thickness in the range of 0.1 mm to 5.0 mm. If the thickness of the thermoplastic resin sheet 11 is less than 0.1 mm, a large number of sheets are required to obtain the required thickness of the thermoplastic resin layer 3, and the lamination process becomes long. The flexibility is lost and it becomes difficult to form the curved surface shape of the wind turbine blade 1 along the inner surface 7 a of the mold 7. The width of the thermoplastic resin sheet 11 is arbitrary, and a predetermined sheet width (for example, 10 m) is sequentially arranged and laminated.

The thermoplastic resin sheet 11 is preferably a low-temperature thermoplastic resin so that the sheets can be joined at a low temperature. Specifically, a high density polyethylene having a melting point of about 135 ° C., a polyolefin resin such as polypropylene having a melting point of about 150 ° C. to 170 ° C., or the like is used. When a high-melting thermoplastic resin is used, a so-called multilayer sheet having a low-melting resin layer on the surface is preferably used. Examples of the high melting point thermoplastic resin include nylon resin and polyester resin. As the low melting point thermoplastic resin on the surface, a so-called adhesive resin such as acrylic resin, SEBS resin, and EVA resin is preferable.
In addition, you may laminate | stack the thermoplastic resin sheet 11 laminated | stacked by mixing a different kind of thing. For example, a sheet made of a polycarbonate resin such as a vinyl chloride resin or polyethylene excellent in weather resistance and flame retardancy may be used on the outer surface side.
Furthermore, a metal sheet such as aluminum may be laminated on the outermost surface together with a so-called adhesive resin sheet such as an acrylic resin, a SEBS resin, or an EVA resin for lightning strike countermeasures.

Next, since the strength is not sufficient when the wind turbine blade 1 is constituted only by the thermoplastic resin layer 3 made of the laminate of the thermoplastic resin sheets 11, the reinforcing fiber outer layer 4 and the reinforcing fiber inner layer 5 are bonded to both the front and back surfaces. The reinforcing fiber outer layer 4 and the reinforcing fiber inner layer 5 are made of the same material, and are composed of a plurality of sheet-like reinforcing fiber resin sheets 12 in which reinforcing fibers are impregnated with a thermoplastic resin. Here, as the reinforcing fiber, for example, carbon fiber, glass fiber, high-strength organic fiber, or the like can be used. Among them, lightweight and highly rigid carbon fiber is preferable.
The reinforcing fibers are preferably continuous fibers in terms of strength, and the orientation of the reinforcing fibers may be aligned in one direction, or may be aligned in the vertical and horizontal directions perpendicular to each other. Alternatively, the reinforcing fibers may be arranged in a quasi-isotropic manner by arranging them in a direction perpendicular to the vertical and horizontal directions and adding an arrangement in the 45 ° direction. The arrangement of the reinforcing fibers can be selected according to the purpose of use. In general, it is preferable to use the reinforcing fibers arranged in advance so as to cross each other like a woven fabric.

As the thermoplastic resin that binds (restrains) the reinforcing fibers, it is preferable to use a polyolefin resin such as high-density polyethylene or polypropylene that can bond between fibers and layers at low temperatures, similarly to the thermoplastic resin sheet 11.
Further, when a high melting point resin such as nylon or polyester is used as the thermoplastic resin sheet 11, it is desirable to use the above-mentioned adhesive thermoplastic resin so that interlayer bonding can be achieved at a low temperature.
In addition, let the content rate of the reinforced fiber in the reinforced fiber resin sheet 12 be the range of 20-60 volume% with respect to the reinforced fiber resin sheet 12 whole. If the content is less than 20% by volume, the reinforcing effect is small, and it is generally difficult to contain more than 60% by volume, and voids or the like may be generated, leading to a decrease in strength.
Further, the thickness of the reinforcing fiber resin sheet 12 is not particularly limited, but if it is too thick, it is difficult to stack the reinforcing fiber resin sheet 12 along the inner surface 7a of the mold 7, and therefore a range of 0.05 mm to 1.00 mm is preferable. . The width | variety of the reinforced fiber resin sheet 12 is normally manufactured by 300 mm-1000 mm.

  The number of laminated thermoplastic resin sheets 11, the number of laminated reinforcing fiber resin sheets 12, and the lamination ratio of both differ depending on the thickness and required strength of the thermoplastic resin molded body to be produced. In the present embodiment, for example, the purpose is to manufacture a wind turbine blade 1 that is a huge thermoplastic resin molded body. Therefore, the number of laminated layers of the thermoplastic resin sheet 11 and the reinforcing fiber resin sheet 12 is at least 10 or more and 1000 sheets. Is set in the range. If the number of stacked layers exceeds 1000, heating in the mold 7 is difficult, which is not preferable.

Moreover, in the outer skin layer 2 of the windmill blade 1, there is no restriction | limiting in the arrangement | sequence of the thermoplastic resin sheet 11 and the reinforced fiber resin sheet 12, For example, the reinforced fiber resin sheet 12 is divided | segmented alternately between the several thermoplastic resin sheets 11, and is alternately. You may arrange. Alternatively, the reinforcing fiber resin sheets 12 may be arranged together in the middle of the plurality of thermoplastic resin sheets 11.
However, the outer skin layer 2 of the wind turbine blade 1 in the present embodiment is formed by laminating a large number of thermoplastic resin sheets 11 as the thermoplastic resin layer 3, and reinforcing fiber resin as the reinforcing fiber outer layer 4 and the reinforcing fiber inner layer 5 on the front and back sides thereof. It is preferable that the sheets 12 are laminated in a concentrated manner because the rigidity and strength of the wind turbine blade 1 are easily exhibited.

Next, the manufacturing method of the windmill blade 1 by this embodiment is demonstrated based on FIGS.
The thermoplastic resin sheet 11 in the present embodiment has a width of, for example, about 10 m, and the reinforcing fiber resin sheet 12 has a width of usually 1 m or less. Therefore, when the thermoplastic resin sheet 11 is laminated on the inner surface 7 a of the mold 7, there is a gap between the reinforcing fiber resin sheets 12. It is easy to produce. Therefore, on the plane, a plurality of reinforcing fiber resin sheets 12 are arranged in advance without gaps in accordance with the dimensions of the inner surface 7a of the mold 7, and the wide thermoplastic resin sheet 11 is placed thereon and fused. .
Then, on the plane, a required number of thermoplastic resin sheets 11 are laminated on the plurality of reinforcing fiber resin sheets 12, and a plurality of reinforcing fiber resin sheets 12 are further laminated thereon to form a laminate S. . Moreover, it is preferable that the required number of stacked sheets 11 and 12 are partially welded with a laser beam or the like so as not to be displaced from each other.

Next, on the inner surface 7a of the mold 7 shown in FIG. 3 (a), the laminated body S made up of a large number of these stacked sheets 11 and 12 is lifted by a crane or the like along the inner surface 7a of the mold 7. Place it curved to avoid wrinkling. In addition, when the number of the laminated bodies S is large, they may be laminated in a plurality of times.
Further, in order to eliminate air remaining between the thermoplastic resin sheet 11 and the reinforcing fiber resin sheet 12 of the laminate S and the reinforcing fiber resin sheet 12 shown in FIG. The vacuum may be drawn with. Further, the air between the sheets 11 and 12 may be removed by pressing with a roll from the upper side of the laminate S. In this way, each of the plurality of thermoplastic resin sheets 11 and reinforcing fiber resin sheets 12 constituting the laminated body S are laminated in a state of being in close contact with each other as shown in FIG.

And in FIG.3 (b), heat is applied from the lower side of the laminated body S through the inner surface 7a by flowing a high temperature steam through the temperature adjustment pipe 8 of the metal mold 7. The heating temperature of the mold 7 varies depending on the kind of the thermoplastic resin used for the laminate S, and is controlled to a temperature at which the thermoplastic resin can be melted. For example, when high-density polyethylene is used as the thermoplastic resin, it is preferable to control the temperature of the mold 7 in the range of 150 ° C. to 180 ° C.
In addition, when heating the laminated body S, it is preferable to dispose a sheet-like heater not only on the inner surface 7a side of the mold 7 but also on the upper side of the laminated body S and to heat from the upper side in order to promote heating and melting. Note that the air between the sheets may be removed from the end surface by the suction pipe 9 while the laminated body S is heated.

As shown in FIGS. 3C and 5, the thermoplastic resin impregnated in each reinforcing fiber resin sheet 12 is melted in the reinforcing fiber outer layer 4 and the reinforcing fiber inner layer 5 by the heating of the laminated body S, so that carbon fibers are used. And intimately contact each other. In the thermoplastic resin layer 3, a large number of thermoplastic resin sheets 11 are melted and integrated with each other, and the thermoplastic resin is also melted and integrated with each other between the thermoplastic resin sheet 11 and the reinforced fiber resin sheet 12. It becomes.
In order to ensure the bonding of the sheets 11 and 12 between the reinforcing fiber outer layer 4, the thermoplastic resin layer 3, and the reinforcing fiber inner layer 5, the heating time of the laminate S needs 20 to 60 minutes. In 20 minutes or less, an unjoined portion due to insufficient heating tends to occur in the central portion of the laminate S. On the other hand, when heated for more than 60 minutes, the thermoplastic resin may be deteriorated due to oxidation.

When the bonding between the layers of the laminate S is integrated, a half body 1a of the outer skin layer 2 in which the reinforcing fiber outer layer 4, the thermoplastic resin layer 3, and the reinforcing fiber inner layer 5 are integrated is formed. In this state, by cutting away the portion protruding from the inner surface 7 a of the mold 7, the end surface of the half body 1 a is located on the same plane as the upper surface of the mold 7 as shown in FIG.
After the completion of the interlayer bonding of the laminate S, the laminate 7 is cooled by cooling the die 7 by passing cooling water through the temperature adjusting pipe 8 of the die. When cooling, it is preferable to cool from the upper part of the mold 7 by blowing air or the like. Depending on the type of thermoplastic resin employed, for example, when high-density polyethylene is used, it can be removed from the mold 7 if the temperature of the laminate S is reduced to about 70 ° C. In addition, since the adhesiveness to the metal mold | die 7 is low when polyolefin resin is used, removal can be performed easily using a crane etc.

Thus, the back half body 1a and the ventral half body 1b of the wind turbine blade 1 manufactured by the mold 7 are each made of carbon fiber reinforced plastic (CFRP). When the wind turbine blade 1 is manufactured by joining the back half body 1a and the ventral half body 1b, the back half body 1a and the ventral half body 1b cannot be joined by an adhesive because they are thermoplastic resins.
Therefore, as shown in FIG. 6, the end faces 2a and 2b of the back half body 1a and the abdominal half body 1b are brought into contact with each other via, for example, an iron wire mesh 14 and externally applied by microwaves or currents. Heat joining is performed, and the thermoplastic resins of the end faces 2a and 2b are remelted and joined to be integrated. In this way, the wind turbine blade 1 made of carbon fiber reinforced plastic (CFRP) can be manufactured using the thermoplastic resin and the carbon fiber.

  As described above, according to the method for manufacturing the wind turbine blade 1 according to the present embodiment, the plurality of thermoplastic resin sheets 11, the reinforcing fiber outer layer 4, and the inner layer 5 that form the thermoplastic resin layer 3 laminated in the mold 7 are provided. A plurality of reinforcing fiber resin sheets 12 formed are heated, and the sheets are thermally welded to each other and integrated and cooled, whereby a wind turbine blade 1 made of a thermoplastic resin molded body is converted into a conventional thermosetting resin molded body. Can be manufactured in a shorter manufacturing cycle.

And the windmill blade 1 which consists of a thermoplastic resin molding by this embodiment can be reduced in weight compared with the thermosetting resin molding (GFRP) which consists of thermosetting resins, such as the conventional glass fiber and an epoxy resin. The thickness can be increased, the rigidity is almost equivalent, and the carbon fiber is more expensive than the glass fiber, but the manufacturing process can be shortened, so that the manufacturing cost when manufacturing a large resin molded body such as the wind turbine blade 1 is almost reduced. It can be suppressed equally.
Further, when the wind turbine blade 1 of the thermoplastic resin molded body is discarded, it can be pulverized and extruded to be recycled to other resin products. This is the conventional thermosetting that is difficult to recycle. Compared to a resin molded body, it can be reused economically without waste of resources.

  The present invention is not limited to the wind turbine blade 1 and the manufacturing method thereof according to the first embodiment described above, and can be appropriately changed or replaced without departing from the gist of the present invention. Are also included in the present invention. Other embodiments and modifications of the present invention will be described below, but the same reference numerals are used for the same or similar parts and members of the above-described embodiments, and description thereof will be omitted.

Next, the manufacturing method of the windmill blade 1 as a thermoplastic resin molding by 2nd embodiment of this invention is demonstrated based on FIGS.
In FIG. 7, a plurality of reinforcing fiber resin sheets 12 are stacked and arranged on a plane, and a thermoplastic resin sheet 11 is stacked and mounted on the reinforcing fiber resin sheet 12 in a necessary number. Further, a necessary number of reinforcing fiber resin sheets 12 are stacked and placed on the thermoplastic resin sheet 11. Moreover, the reinforcing fiber resin sheet 12 forming the reinforcing fiber inner layer 5 has a larger number of laminated sheets than the reinforcing fiber resin sheet 12 forming the reinforcing fiber outer layer 4 at the central portion where the strength of the half body 1a of the wind turbine blade 1 is relatively small. Is set.

Next, these laminates S are lifted by a crane or the like and placed on the inner surface 7a of the mold 7 as shown in FIG. And between the inner surface 7a and the laminated body S, the peeling sheet made from Teflon (trademark) may be installed so that peeling after thermoforming may be easy, for example.
In this state, high-temperature steam is circulated through the temperature adjustment pipe 8 in the mold 7 to raise the mold temperature, and heating is performed from the lower surface of the laminate S. Further, an opening of the suction pipe 9 is provided on the end face and the bottom surface of the laminate S to perform vacuum suction, thereby removing air between the sheets 11 and 12 and increasing the heating efficiency. At that time, the sheet 16 is covered on the upper surface of the laminate S so that air can be sucked by the suction pipe 9 from the end faces of the laminated thermoplastic resin sheet 11 and the reinforcing fiber resin sheet 12, and the inside can be maintained in a state close to a vacuum. I am doing so.
The sheets 11 and 12 are sufficiently joined by heating to be integrated, and the thermoplastic resin layer 3 and the upper and lower reinforcing fiber outer layers 4 and 5 are joined to each other.

  Thus, after the joining between the sheets 11 and 12 of the laminated body S is sufficient, the back half body 1a of the wind turbine blade 1 obtained by flowing the cooling water into the temperature adjusting pipe 8 and cooling the mold 7 is obtained. Is removed from the mold 7. As shown in FIG. 9, the obtained back half body 1 a is formed such that the thickness of the central portion of the reinforcing fiber inner layer 5 is thicker than both ends, and the strength is increased. And the windmill blade 1 is obtained by cutting off both ends of the back side half body 1a and the abdominal side half body 1b, and fuse | melting and joining end surfaces 2a and 2b mutually.

  As described above, in the wind turbine blade 1 according to the second embodiment, the central portion that is separated from the joint portion of the back half body 1a and the ventral half body 1b joined to each other is set to be thick with the reinforcing fiber resin sheet 12. There is an advantage that the strength of the wind turbine blade 1 can be increased.

  In addition, although the back side half body 1a of the wind turbine blade 1 which is the thermoplastic resin molded body according to the first embodiment described above integrally forms the reinforcing fiber outer layer 4 and the reinforcing fiber inner layer 5 on the front and back surfaces of the thermoplastic resin layer 3, You may employ | adopt the structure which joins the reinforced fiber outer layer 4 or the reinforced fiber inner layer 5 only to either one of front and back. In this case, it is preferable to form the reinforcing fiber outer layer 4 in order to improve the strength of the outer surface of the wind turbine blade 1.

Moreover, in each embodiment mentioned above, when heating and joining the laminated body S mounted on the metal mold | die 7, it replaces with the means which distribute | circulates high temperature steam in the temperature control pipe 8, and heats it. The laminated body S may be melted and joined by setting the atmospheric temperature of the entire room where the mold 7 is installed to a high temperature.
Moreover, in 2nd embodiment, it replaces with the structure which makes thickness of the center part of the reinforced fiber inner layer 5 larger than both ends, and makes thickness of the center part of the thermoplastic resin sheet 11 which forms the thermoplastic resin layer 3 from both ends. You may set large.

Next, a wind turbine blade 1 made of carbon fiber and a thermoplastic resin according to the first embodiment of the present invention is used as an example, and a wind turbine blade made of a conventional glass fiber and a thermosetting resin is used as a conventional example. The characteristics of the wind turbine blade 1 which was the formed body were tested. In addition, the volume of the windmill blade 1 by an Example and a prior art example was made the same.
In the examples, as shown in the first embodiment, the back half body 1a and the abdomen half body 1b of the wind turbine blade 1 are obtained from a reinforced fiber resin sheet 12 in which carbon fiber is impregnated with a high-density polyethylene resin as a thermoplastic resin. A carbon fiber composite (CFRP) wind turbine blade 1 in which a thermoplastic resin layer 3 made of high-density polyethylene resin was melted and integrated between the reinforcing fiber outer layer 4 and the reinforcing fiber inner layer 5 was manufactured.
On the other hand, in the conventional example, a glass fiber composite (GFRP) wind turbine blade was manufactured by impregnating the entire wind turbine blade with an epoxy resin as a thermosetting resin.

  When the volume%, weight, and thickness of each fiber amount of these Examples and Conventional Examples are compared, Table 1 below shows that the Conventional Example is 100.

Further, the relationship between the displacement position (mm) in the width direction and the rigidity (load: N) according to the example and the conventional example is shown in FIG. 10 as a graph. From Table 1 and FIG. 10, even if the fiber amount of the carbon fiber of the example was almost 1/3 of the conventional example, the physical properties were almost equivalent, and the thickness of the example could be increased and the weight could be reduced.
Furthermore, in the production methods of the example and the conventional example, the cooling time of the mold 7 after use was 20 minutes because it may be about 80 ° C. in the example. In the case where the molding is further performed, in the embodiment using the thermoplastic resin, there is no problem even if the sheet is directly laminated on a mold of about 80 ° C. On the other hand, since the epoxy resin is a thermosetting resin in the conventional example, the cooling time was 60 minutes because the mold was cooled to room temperature for each molding so that the viscosity of the epoxy resin did not increase during the next molding.

In addition, the installation time of each resin or woven fabric (fiber) to the mold 7 was 90 minutes in the conventional example, but in the example, it was 30 minutes because the laminate S could be placed with a crane. Further, in the conventional example, it took 30 minutes to inject the thermosetting resin into the mold 7. However, since the example is a sheet shape, the resin injection is not required. Further, the time required for heat curing and cooling was 50 minutes in the example, but it took 120 minutes in the conventional example.
The total production time was 100 minutes in the example and 300 minutes in the conventional example, and the production was completed in 1/3 of the conventional example. Therefore, although carbon fiber is expensive compared with glass fiber, since the time of the manufacturing process is short, it was able to be manufactured at the same cost.

  As described above, according to the method for manufacturing a thermoplastic resin molded body of the present invention, it is possible to manufacture not only the wind turbine blade 1 but also a two-dimensional or three-dimensional large-sized building along the mold shape. Since this building is a thermoplastic resin, the strength is improved by fusing the joint surfaces to fuse the buildings together and further increasing the size, or by fusing thermoplastic reinforcing ribs on at least one side. It is also possible to make it. In the case of a reinforcing rib that is not a thermoplastic resin, it can be joined to the thermoplastic resin by fusion bonding with an adhesive resin material.

Further, in each of the above-described embodiments, as the reinforcing fiber resin sheet 12 of the reinforcing fiber outer layer 4 and the reinforcing fiber inner layer 5 in the wind turbine blade 1, a carbon fiber impregnated with a thermoplastic resin is used. Glass fiber, high-strength organic fiber, or the like may be used.
In addition, the thermoplastic resin molded body according to the present invention does not necessarily need to use the reinforcing fiber outer layer 4 and the reinforcing fiber inner layer 5 of the reinforcing fiber resin sheet 12, and a plurality of thermoplastic resin sheets 11 are laminated and fused to be integrated. You may comprise only the thermoplastic resin layer 3. FIG.
The reinforcing fiber outer layer 4 and the reinforcing fiber inner layer 5 in the wind turbine blade 1 are included in the reinforcing fiber resin layer.

In addition, although each embodiment of this invention demonstrated the manufacturing method of the windmill blade 1 used for wind power generation, and the windmill blade 1 as a thermoplastic resin molded object which can be manufactured, this invention is limited to such embodiment. Instead, for example, the present invention can be applied to various large thermoplastic resin molded articles having a width of 10 m or more. Specifically, in addition to the huge windmill blade 1, it can also be applied to a large building such as a floor plate for civil engineering construction, a roofing material, a body used in a vehicle such as a ship, an aircraft, and a trailer.
Further, the present invention has been described using a wind turbine blade as an embodiment and using a die having a substantially arc-shaped cross section. Instead, a thermoplastic sheet laminated using a die having a substantially circular cross section. May be laminated in an annular shape. The large thermoplastic resin molded body produced in this case can be applied to large pipes such as natural gas pipelines.

  Next, a method for manufacturing a thermoplastic resin molded body according to a third embodiment of the present invention and a thermoplastic resin molded body formed by using this manufacturing method will be described with reference to FIG.

  The method for producing a thermoplastic resin molded body according to the third embodiment comprises a step of placing a plurality of thermoplastic resin sheets 11 and reinforcing fiber resin sheets 12 to form a laminate S, as shown in FIG. The laminated body S is heated and melted to be integrated with each other, and the laminated body S is compressed by a pair of molds 17 and 18 so that the molten thermoplastic resin flows and a molded body (thermoplastic A step of forming a part of the resin molded body) 20 thicker than other regions, and a step of taking out the molded body 20 integrated after cooling from the molds 17 and 18.

  In the third embodiment, the mold surface (inner surface) 17a of one mold 17 is formed in a concavo-convex shape, and when the laminated body S heated and melted is compressed with the pair of molds 17 and 18, A part of the laminate S is strongly pressed (compressed) by the convex portion 17b of one mold 17, and the molten thermoplastic resin in this portion flows toward the concave portion 17c (in the concave portion 17c).

  Therefore, in the method for producing a thermoplastic resin molded body according to the third embodiment (and the thermoplastic resin molded body 20), in addition to the same effects as those of the first embodiment and the second embodiment, the laminate S is a fiber. Since the laminated body S is formed by heating and melting each other to be integrated, the laminated body S is formed into a desired uneven shape (or inclined shape, curved surface). The shape of the mold surface 17a is compressed by the molds 17 and 18 provided on the mold surface 17a, so that the molten thermoplastic resin flows and a part of the mold surface 17a is made thicker than the other regions. Is possible.

As a result, the molded body 20 having partially different thicknesses can be molded by compression molding at a relatively low pressure, and a molded body having a complicated shape such as the skin-rib structure shown in FIG. 11 can be easily formed. It becomes possible to manufacture.
In particular, when a huge structure such as a windmill is compression-molded, the production method of the present invention that can be molded at a low pressure is extremely useful.

  Next, a method for manufacturing a thermoplastic resin molded body 20 and an example of the thermoplastic resin molded body 20 according to the third embodiment of the present invention will be described.

(Molding of thermoplastic resin sheet)
In this example, a polypropylene resin sheet produced as follows was used as the thermoplastic resin sheet.
Polypropylene resin (EA9: Nippon Polypropylene Co., Ltd.) was melt-kneaded with a single screw extruder, and then extruded through a T-type die having a width of 400 mm. Then, it cooled and picked up with a pair of cooling roll, and shape | molded by thickness 0.3mm and width 350mm.

(Formation of thermoplastic resin sheet for impregnation)
A polypropylene resin sheet produced as follows was used as the impregnating thermoplastic resin sheet.
Polypropylene resin (MA04A: Nippon Polypropylene Co., Ltd.) was melt-kneaded with a single screw extruder and then extruded through a T-die having a width of 400 mm. Then, it cooled and picked up with a pair of cooling roll, and shape | molded by thickness 0.15mm and width 350mm.

(Reinforced fiber resin sheet: glass fiber resin sheet)
Next, TEMPEX (104RG601: Bond Laminate product) was used as a reinforcing fiber resin sheet disposed on one side of the laminate. This reinforcing fiber resin sheet is obtained by impregnating a plain woven fabric of glass fiber with a polypropylene resin, and has a thickness of 0.55 mm.

(Reinforced fiber resin sheet: carbon fiber resin sheet)
Next, as the reinforcing fiber resin sheet disposed on the other surface side of the laminate, a carbon fiber resin sheet produced as follows was used.
Carbon fiber tows (TC35, 24K: Taiwan plastic products) were aligned on the above-described thermoplastic resin sheet for impregnation so that the fiber directions were aligned in one direction and the distance between the tow centers was 14 mm. Then, the carbon fiber tow was impregnated with the molten thermoplastic resin using a 350 mm square heating press (Toyo Seiki Co., Ltd. product) heated to 200 ° C. At this time, the carbon fiber tow was impregnated with the thermoplastic resin at a pressure of 1 MPa and a pressurization time of 1 minute. Then, the carbon fiber resin sheet of 300 mm square and thickness 0.2mm was obtained by cooling material.

(Integration process of laminated body)
And after cutting the above-mentioned material into the size of width 100mm and length 200mm, it laminates | stacks in order of 6 sheets of carbon fiber resin sheets, 20 sheets of thermoplastic resin sheets, and 5 sheets of glass fiber resin sheets. Formed.
In addition, an iron plate having a thickness of 10 mm was placed on the laminate, and the laminate was heated in a hot air oven with some pressure applied to the whole. At this time, the oven temperature was 200 ° C. and the heating time was 30 minutes. Thus, it was confirmed that the laminate was heated at a temperature of 170 ° C. or higher, which is the melting temperature of polypropylene, and the layers were fused and integrated.

(Process of compressing the laminated body with a pair of molds to obtain a thermoplastic resin molded body partially different in thickness)
Next, the laminated body integrated by heating and melting was put in a mold and clamped with a pair of upper and lower molds. One mold (lower mold) has a flat mold surface, whereas the other mold has a mold surface with a predetermined width and is arranged alternately and regularly. A plurality of convex portions and concave portions are provided.
Moreover, in the present Example, the laminated body was put in the mold so that the glass fiber resin sheet was disposed on the mold surface side on the plane of one mold.
This mold was compressed with a 350 mm square heating press (product of Toyo Seiki Co., Ltd.). In this compression step, the mold was not heated and a load of 200 kgf was applied to the pair of molds. As a result, the pressure applied to the laminate in the mold was calculated to be approximately 1 kg / cm ² .
The laminated body is cooled for 10 minutes while maintaining this pressurized state, and then the thermoplastic resin molded body formed to have a partially different thickness is taken out from the mold.
The molded body thus produced had a so-called skin rib structure, and the thickness of the skin portion was about 4 mm and the height of the rib portion was 15 mm.

  As mentioned above, although the manufacturing method and thermoplastic resin molding of the thermoplastic resin molding of 3rd embodiment which concern on this invention were demonstrated, this invention is not limited to said 3rd embodiment, 1st implementation Appropriate modifications can be made without departing from the scope of the present invention, including modifications of the embodiment, the second embodiment, and the third embodiment.

  Further, the configurations of the first embodiment and the second embodiment may be appropriately applied or combined.

  Further, in the present embodiment, the mold surface 17a of one mold 17 is formed in an uneven shape, and the mold surface 18a of the other mold 18 is formed in a flat shape. The mold surface 18a is also formed into a concavo-convex shape, and the thermoplastic resin molded body 20 is manufactured by making the one surface side formed by the reinforcing fiber outer layer 4 and the other surface side formed by the reinforced fiber inner layer 5 into a concavo-convex shape. You may do it. Further, the uneven shape according to the present invention may be an inclined shape, a curved surface shape, or the like.

DESCRIPTION OF SYMBOLS 1 Windmill blade 1a Back half body 1b Abdominal half body 3 Thermoplastic resin layer 4 Reinforcement fiber outer layer 5 Reinforcement fiber inner layer 7 Mold 8 Temperature adjustment pipe 9 Suction pipe 11 Thermoplastic resin sheet 12 Reinforcement fiber resin sheet 17 One gold Mold 17a Mold surface (inner surface)
17c Convex part 17c Concave part 18 Other mold 18a Mold surface (inner surface)
20 Thermoplastic Resin Molded Body S Laminate

Claims (10)

Placing and stacking a plurality of thermoplastic resin sheets in a mold; and
A step of heating and laminating the laminated thermoplastic resin sheets to form a single piece;
And a step of taking out the integrated molded body of the thermoplastic resin sheet from the mold after cooling, and a method for producing the molded thermoplastic resin body.   2. The thermoplastic resin molding according to claim 1, wherein a reinforcing fiber resin sheet containing reinforcing fibers and thermoplastic resin having higher strength than the thermoplastic resin sheet is laminated on one or both of the front and back surfaces of the plurality of thermoplastic resin sheets. Body manufacturing method.   The method for producing a thermoplastic resin molded body according to claim 2, wherein the laminated thermoplastic resin sheet and reinforced fiber resin sheet are heated by raising the temperature of the mold. After laminating the plurality of thermoplastic resin sheets and the reinforcing fiber resin sheet in a mold,
The method for producing a thermoplastic resin molded body according to claim 2 or 3, wherein air is discharged from end faces of the plurality of thermoplastic resin sheets and the reinforcing fiber resin sheet.   The method for producing a thermoplastic resin molded article according to any one of claims 2 to 4, wherein the reinforcing fibers contained in the reinforcing fiber resin sheet are carbon fibers, glass fibers, or high-strength organic fibers.   A method for manufacturing a thermoplastic resin molded body, wherein a plurality of thermoplastic resin molded bodies manufactured by the method for manufacturing a thermoplastic resin molded body according to any one of claims 1 to 5 are joined to each other.   A wind turbine blade characterized in that a reinforcing fiber resin layer containing a reinforcing fiber and a thermoplastic resin having higher strength than the thermoplastic resin layer is laminated and integrated on the surface of the thermoplastic resin layer.   The wind turbine blade according to claim 7, wherein a part of the thermoplastic resin layer or the reinforcing fiber resin layer is formed thicker than other regions. A step of placing a plurality of thermoplastic resin sheets and reinforcing fiber resin sheets to form a laminate;
A step of heating the laminate and fusing together a plurality of thermoplastic resin sheets and reinforcing fiber resin sheets,
By compressing the laminated body with a pair of molds, the molten thermoplastic resin is made to flow, and a part of the molded body is formed thicker than other regions, and the molded body integrated after cooling is molded into the mold. And a step of removing from the thermoplastic resin molded body. It is formed using the method for producing a thermoplastic resin molded body according to claim 9,
It is provided with a thermoplastic resin layer that is thicker than other regions in part, and is provided with a reinforced fiber resin layer containing reinforcing fibers and a thermoplastic resin on the surface side of the thermoplastic resin layer, and is formed in an uneven shape. A thermoplastic resin molded product.