JP2020045867A - Windmill blade, connection, connection method and process of manufacture windmill blade - Google Patents

Abstract

To connect a spar cap and a shear web.SOLUTION: A windmill blade comprises: a spar cap 13 having an external surface 13a and an inner surface 13b; a connection auxiliary member 31 having at least a pair of wall parts 311 built on the inner surface side of the spar cap; a shear web 20 located between the pair of wall parts and including a first end 20a facing the inner surface of the spar cap and a second end opposite the first end and having at least a first reinforcement fiber resin sheet 21 including a first surface and a second surface extending from the first end to the second end; and an adhesive 32 containing a resin, which is in contact with the wall part and the shear web in between the pair of wall parts. The second surface of the first reinforcing fiber resin sheet has a plurality of base regions 22 and a plurality of rib regions 23 protruding to a side away from the first surface, and the adhesive is located at least partially between the plurality of rib regions.SELECTED DRAWING: Figure 8

Description

  The present invention relates to a wind turbine blade, a connection part, a connection method, and a wind turbine blade manufacturing method.

  In recent years, among renewable energies, wind power generation, which has excellent cost performance, has attracted attention. In particular, large wind turbines generate a large amount of power per machine and are excellent in cost performance. Specifically, 60 m class wind turbine blades are currently mainly used in Europe, but it is expected that 75 to 150 m class wind turbine blades will be used in the future.

  However, weight and strength are important issues in increasing the size of a wind turbine blade. With respect to such a problem, for example, Patent Literature 1 and Patent Literature 2 disclose a technique using carbon fiber as a reinforcing fiber of a spar cap of a wind turbine blade. Carbon fiber is a lightweight and highly elastic fiber, which is shown to be lighter than a spar cap using glass fiber and to improve performance such as strength. Patent Literature 3 discloses that a sheet including carbon fibers and having a linear convex portion is attached to the surface of a wind turbine blade.

JP 2013-151927 A JP-A-2006-125441 WO 2017/209300

  Replacing the spar cap or the like with carbon fiber alone may not provide sufficient strength and weight reduction of a larger wind turbine blade. A further consideration is to replace the internal structure of the shear web connected to the spar cap from glass fibers to carbon fibers.

  The inventors of the present application have simply replaced the glass fiber share web with carbon fiber. However, in this case, a large amount of carbon fiber was required. In addition, if the method of pultrusion used when manufacturing a glass fiber share web is to be applied when manufacturing a carbon fiber share web, the pultrusion itself is difficult due to the difference in resin impregnation. there were.

  The present inventors have further studied and found that it is possible to manufacture a shear web having excellent mechanical properties by combining a sheet containing carbon fibers and having a convex portion formed thereon with a substrate. However, when it is intended to directly bond the shear web having the projections to the spar cap, as in the case of the above-described shear web containing carbon fibers, the gap between the shear web and the spar cap due to the projections. Therefore, it was difficult to secure a contact area, and it was difficult to obtain sufficient mechanical strength.

  The present invention provides a spar cap having at least a spar cap having an outer surface and an inner surface, a pair of wall portions built on the inner surface side of the spar cap, and a connection assisting member located between the pair of wall portions. A shear web including a first end facing the inner surface of the cap and a second end opposite the first end, wherein a first web extends from the first end to the second end. A shear web having at least a first reinforcing fiber resin sheet including a surface and a second surface, and an adhesive containing a resin, which is in contact with the wall portion and the shear web between a pair of the wall portions; The second surface of the 1-reinforced fiber resin sheet has a plurality of base regions and a plurality of rib regions protruding on a side away from the first surface, and the adhesive is at least partially provided with a plurality of the Rib area Positioned between a wind turbine blade.

  In the wind turbine blade according to the present invention, the connection auxiliary member further includes a bottom portion connected to ends of the pair of wall portions on the spar cap side and extending along the inner surface of the spar cap, May be in contact with the wall portion, the bottom portion, and the share web.

  In the wind turbine blade according to the present invention, the bottom portion of the connection assisting member may extend outward from a pair of the wall portions in a direction in which an inner surface of the spar cap expands.

  In the wind turbine blade according to the present invention, the plurality of rib regions of the first reinforcing fiber resin sheet may extend linearly in parallel with each other.

  In the wind turbine blade according to the present invention, the first reinforcing fiber resin sheet may include carbon fiber and a thermoplastic resin.

  In the wind turbine blade according to the present invention, the first reinforcing fiber resin sheet includes a first sheet material, a core material that is located on one surface of the first sheet material, and configures the rib region, and the core material. A second sheet material laminated on the first sheet material so as to cover, one of the first sheet material and the second sheet material includes continuous fibers extending in one direction, and the other includes: It may include continuous fibers extending in multiple directions.

  In the wind turbine blade according to the present invention, the shear web includes a second reinforcing fiber resin sheet provided on a first surface side of the first reinforcing fiber resin sheet, and the second reinforcing fiber resin sheet includes the first reinforcing fiber resin sheet. The second reinforcing fiber resin sheet has a first surface facing the first surface of the reinforcing fiber resin sheet, and a second surface located on a side opposite to the first surface of the second reinforcing fiber resin sheet. The second surface of the sheet has a plurality of the base regions and a plurality of the rib regions protruding away from the first surface of the second reinforcing fiber resin sheet, and the adhesive is at least partially Preferably, the second reinforcing fiber resin sheet may be located between the plurality of rib regions on the second surface.

  The present invention provides a spar cap having an outer surface and an inner surface, wherein the inner surface has a first end facing the inner surface and a second end located opposite the first end. A connecting portion for connecting portions, wherein the share web has at least a first reinforcing fiber resin sheet including a first surface and a second surface extending from the first end to the second end; (1) The second surface of the reinforcing fiber resin sheet has a plurality of base regions and a plurality of rib regions protruding to a side away from the first surface, and the connecting portion is provided between the plurality of base regions and the shear web. A connection assisting member having at least a pair of walls erected on the inner surface side of the spar cap such that a first end is located, and being in contact with the wall and the shear web between the pair of walls; , An adhesive containing resin, For example, the adhesive material is located between the at least partially the plurality of rib region is a connection part.

  In the connecting portion according to the present invention, the connection assisting member further includes a bottom portion connected to ends of the pair of wall portions on the spar cap side and extending along the inner surface of the spar cap, wherein the adhesive material May be in contact with the wall portion, the bottom portion, and the share web.

  In the connecting portion according to the present invention, the bottom portion of the connection assisting member may extend outward from a pair of the wall portions in a direction in which an inner surface of the spar cap expands.

  In the connecting portion according to the present invention, the shear web includes a second reinforcing fiber resin sheet provided on a first surface side of the first reinforcing fiber resin sheet, and the second reinforcing fiber resin sheet includes the first reinforcing fiber resin sheet. The second reinforcing fiber resin sheet has a first surface facing the first surface of the reinforcing fiber resin sheet, and a second surface located on a side opposite to the first surface of the second reinforcing fiber resin sheet. The second surface of the sheet has a plurality of the base regions and a plurality of the rib regions protruding away from the first surface of the second reinforcing fiber resin sheet, and the adhesive is at least partially Preferably, the second reinforcing fiber resin sheet may be located between the plurality of rib regions on the second surface.

  The present invention provides a spar cap having an outer surface and an inner surface, wherein the inner surface has a first end facing the inner surface and a second end located opposite the first end. A connection method for connecting parts, wherein the share web has at least a first reinforcing fiber resin sheet including a first surface and a second surface that extend from the first end to the second end. (1) The second surface of the reinforcing fiber resin sheet has a plurality of base regions and a plurality of rib regions protruding on a side away from the first surface, and the connection method includes the steps of: A connection assisting member installation step of providing a connection assisting member having at least a pair of wall portions, and a shear for disposing the share web such that the first end of the shear web is located between the pair of wall portions. Web placement process Supplying a reactive resin between the wall portions so as to be in contact with the wall portion and the shear web and at least partially between the plurality of rib regions. And a reactive resin curing step of curing the reactive resin.

  In the connection method according to the present invention, the reactive resin may be a thermosetting resin, an ultraviolet curable resin, or a moisture curable resin.

  The present invention is a method for manufacturing a windmill blade, comprising the above-described connection method.

  According to the connection method of the present invention, the supercap and the share web can be connected.

FIG. 1 is a diagram illustrating an example of a wind turbine to which a wind turbine blade according to an embodiment of the present invention can be applied. FIG. 2 is a sectional view taken along the line II-II in FIG. FIG. 3 is a perspective view of the share web in the present embodiment. FIG. 4 is a sectional view taken along the line IV-IV in FIG. FIG. 5 is a perspective view of the first reinforcing fiber resin sheet. FIG. 6 is a sectional view taken along the line VI-VI in FIG. FIG. 7 is a diagram for explaining a method for manufacturing the first reinforcing fiber resin sheet. FIG. 8 is a cross-sectional view of the connecting portion according to the present embodiment. FIG. 9 is a diagram for describing a first modification of the connection assisting member. FIG. 10 is a view for explaining a second modification of the connection assisting member. FIG. 11 is a cross-sectional view of a connection portion according to a comparative example. FIG. 12 is a view for explaining a modification of the connection assisting member. FIG. 13 is a view for explaining a modification of the connection assisting member. FIG. 14 is a diagram illustrating a modified example of the first reinforcing fiber resin sheet. FIG. 15 is a diagram for describing a first modification of the share web. FIG. 16 is a diagram for describing a first modification of the share web. FIG. 17 is a diagram for describing a first modification of the share web. FIG. 18 is a diagram illustrating a second modification of the share web.

  Hereinafter, an embodiment of a wind turbine blade of the present invention will be described with reference to the drawings. In the present embodiment, a windmill blade of a windmill described later will be described as an example. 1 to 10 are diagrams for explaining an embodiment according to the present invention. In addition, in the drawings attached to the present specification, for convenience of understanding, the scales and the dimensional ratios in the vertical and horizontal directions are appropriately changed from those of the actual ones and exaggerated. In addition, the dimensional ratios in the drawings may be partially omitted from the drawings for convenience of description.

(Windmill)
First, a windmill having a windmill blade according to the present embodiment will be described. FIG. 1 is a diagram of a wind turbine for wind power generation. The wind turbine 80 shown in FIG. 1 can rotate with a column 82 erected on the foundation B, a nacelle 83 installed at the upper end of the column 82, and a substantially horizontal line provided on the nacelle 83 as a rotation axis. And a rotor head 84. The wind turbine 80 shown in FIG. 1 further has a plurality of (for example, three) wind turbine blades 1 radially arranged around the rotation axis of the rotor head 84. The force of the wind hitting the wind turbine blades 1 from the direction of the rotation axis of the rotor head 84 is converted into power for rotating the rotor head 84 about the rotation axis.

(Windmill wing)
Next, the wind turbine blade 1 according to the present embodiment will be described. FIG. 2 is a cross-sectional view of the wind turbine blade 1 along the II-II direction in FIG. The wind turbine blade 1 shown in FIG. 2 includes a skin material 11, a leading edge intermediate layer material 12, a spar cap 13, a trailing edge intermediate layer material 14, a shear web 20, and an endothelial material 17. The leading edge intermediate layer material 12 and the trailing edge intermediate layer material 14 are made of, for example, a resin foam such as PVC or wood such as balsa. In the wind turbine blade 1, a portion where the outer skin material 11, the leading edge intermediate layer material 12 and the endothelial material 17 overlap, and a portion where the outer skin material 11, the trailing edge intermediate layer material 14 and the endothelial material 17 overlap are the outer skin material 11 and the inner skin material. 17 as a skin material, and a leading edge intermediate layer material 12 or a trailing edge intermediate layer material 14 as a core material. In the wind turbine blade 1 shown in FIG. 2, the outer skin material 11 and the inner skin material 17 are each formed (configured) of fiber reinforced plastic (FRP).

  In the present embodiment, as shown in FIG. 2, one spar cap 13 is provided on each of the back side (upper side in FIG. 2) and the abdomen side (lower side in FIG. 2) of the wind turbine blade 1. . The spar cap 13 has an outer surface 13a located outside the wind turbine blade 1 and an inner surface 13b located inside the wind turbine blade 1 in the sectional view of FIG. The spar cap 13 is formed (configured) of, for example, fiber reinforced plastic (FRP). The spar cap 13 may be a member in which fiber reinforced plastics are laminated in multiple layers. The inner surface of the spar cap 13 may be a curved surface as shown in FIG. 2 or a flat surface (not shown).

  The share web 20 will be described. The shear web 20 is a member for ensuring the strength of the wind turbine blade 1. As shown in FIG. 2, the shear web 20 includes a first end 20a and a second end 20b opposite to the first end 20a. As shown in FIG. 2, when one spar cap 13 is provided on each of the back side and the abdomen side of the wind turbine blade 1, the first end 20 a of the shear web 20 is connected to one of the spar caps 13, for example, The second end 20b of the shear web 20 faces the other inner surface 13b of the spar cap 13, for example, the inner surface 13b of the other spar cap 13.

  In the present embodiment, the wind turbine blade 1 further includes a connecting portion 30 for connecting the spar cap 13 and the shear web 20. Details of the connection unit 30 will be described later.

  The share web 20 will be described in more detail. FIG. 3 is a perspective view of share web 20 according to the present embodiment. FIG. 4 is a cross-sectional view along the IV-IV direction in FIG. Share web 20 according to the present embodiment has at least first reinforcing fiber resin sheet 21. In the example shown in FIGS. 3 and 4, the shear web 20 includes a first reinforcing fiber resin sheet 21, a base sheet 28, and an adhesive located between the first reinforcing fiber resin sheet 21 and the base sheet 28. And a layer 29. In the following description, the surface of the first reinforcing fiber resin sheet 21 on the side of the base sheet 28 is referred to as a first surface 21a, and the surface located on the opposite side to the base sheet 28 is also referred to as a second surface 21b. . As shown in FIG. 4, the first surface 21a and the second surface 21b of the first reinforcing fiber resin sheet 21 extend from the first end 20a of the shear web 20 to the second end 20b. As shown in FIG. 4, the second surface 21 b of the first reinforcing fiber resin sheet 21 has a base region 22 and a plurality of rib regions 23 protruding further away from the base sheet 28 than the base region 22. . Further, a surface of the second surface 21b that extends so as to connect the bottom surface 22a located in the base region 22 and the top surface 23a located on the side of the rib region 23 farthest from the base region 22 is also referred to as a side surface 24. .

  In the first reinforcing fiber resin sheet 21 according to the present embodiment, a plurality of rib regions 23 are arranged in one direction, and each rib region 23 is lined in a direction non-parallel to one direction which is the arrangement direction. It extends in a shape. In the example shown in FIG. 4, a plurality of rib regions 23 are arranged in the X direction, and each rib region 23 linearly extends in the Y direction orthogonal to the X direction. The plurality of rib regions 23 are arranged with an interval therebetween. The base region 22 is formed between two rib regions 23 adjacent in the arrangement direction.

  As an example, the dimensions shown in FIG. 4 can be designed as follows. The width w1 of each base region 22 along the X direction can be 2 mm or more and 50 mm or less. Further, the width w2 of each rib region 23 along the X direction can be 1 mm or more and 50 mm or less. The height h1 of each rib region 23 can be 1 mm or more. The height h1 of each rib region 23 can be, for example, 50 mm or less. The first reinforcing fiber resin sheet 21 shown in FIGS. 3 and 4 is a sheet-like member as a whole. The angle formed by the side surface 24 of the first reinforcing fiber resin sheet 21 with respect to the normal direction of the base region 22 may be not less than −30 ° and not more than + 30 °. In the example shown in FIG. 4, when the straight line L1 extending in the Z direction which is the normal direction of the base region 22 is included in the side surface 24, that is, the angle formed by the side surface 24 with respect to the normal direction of the base region 22 is 0. ° is shown.

  The base sheet 28 is a member bonded to the first reinforced fiber resin sheet 21 for the purpose of reinforcing the first reinforced fiber resin sheet 21 or the like. The base sheet 28 includes, for example, one or more of resin, metal, and ceramics. The base sheet 28 may include a carbon fiber and a thermoplastic resin described later, like the first reinforcing fiber resin sheet 21. The thickness of the base sheet 28 is, for example, 0.1 cm or more and 10 cm or less. Since the shear web 20 further includes the base sheet 28 in addition to the first reinforcing fiber resin sheet 21, the thickness of the shear web 20 can be ensured.

  The adhesive layer 29 is a layer including an adhesive for bonding the base sheet 28 and the first reinforcing fiber resin sheet 21. The adhesive layer 29 is, for example, a hot melt adhesive containing a thermoplastic resin. As the thermoplastic resin of the adhesive layer 29, for example, a polyolefin resin such as polypropylene, a polyester resin, a polyamide resin, or the like can be used. When the adhesive layer 29 contains a thermoplastic resin, the adhesive layer 29 is softened by heating and can be removed from the shear web 20 and recovered. For this reason, the recyclability of the share web 20 can be improved.

  Next, the first reinforcing fiber resin sheet 21 will be described in detail with reference to FIGS. FIG. 5 is a perspective view of the first reinforcing fiber resin sheet 21. FIG. 6 is a cross-sectional view along the VI-VI direction in FIG. In the example shown in FIGS. 5 and 6, the first reinforcing fiber resin sheet 21 includes a first sheet material 25 and a plurality of surfaces provided on the surface of the first sheet material 25 located on the second surface 21b side. And a second sheet material 27 laminated on the first sheet material 25 so as to cover the core material 26. Although not shown, the first sheet material 25, the core material 26, and the second sheet material 27 may be bonded via an adhesive layer. The area of the first reinforcing fiber resin sheet 21 in which the second sheet material 27 covers the core material 26 is the above-described rib area 23. Further, a region of the first reinforcing fiber resin sheet 21 where the second sheet material 27 does not cover the core material 26 is a base region 22.

  The first reinforcing fiber resin sheet 21 contains carbon fiber and a thermoplastic resin. In the present embodiment, the first reinforcing fiber resin sheet 21 is a member manufactured using a so-called carbon fiber reinforced resin (Carbon Fiber Reinforced Plastics) material. Therefore, the first reinforcing fiber resin sheet 21 has features such as light weight and high strength, that is, high specific strength.

  At least one of the first sheet material 25, the second sheet material 27, and the core material 26 included in the first reinforced fiber resin sheet 21 shown in FIGS. 5 and 6 includes the above-described carbon fiber reinforced resin. Hereinafter, an example of the material of the first sheet material 25, the second sheet material 27, and the core material 26 will be described.

  First, the materials of the first sheet material 25 and the second sheet material 27 will be described. The first sheet material 25 and the second sheet material 27 include, for example, a fiber and a synthetic resin impregnated in the fiber. The fibers contained in the first sheet material 25 and the second sheet material 27 may be glass fibers or carbon fibers. When the first sheet material 25 and the second sheet material 27 include carbon fiber, the first sheet material 25 and the second sheet material 27 are made lighter and have higher strength as compared with the case where glass fiber is included. be able to. In addition, since carbon fibers have higher thermal conductivity than glass fibers, when the first reinforcing fiber resin sheet 21 is heat-bonded to the base sheet 28 in the method for manufacturing the shear web 20 described later, the bonding is more efficiently performed. Heat can be transmitted to the surface. Specifically, the first sheet material 25 and the second sheet material 27 can be manufactured as a portion obtained by impregnating a fibrous base material with a synthetic resin. The fibrous base material is not particularly limited, and may include, for example, unidirectional continuous fibers, may include woven continuous fibers extending in a plurality of directions, or may be cut instead of continuous fibers. It may contain long fibers. Here, the long fiber means a fiber having a length of, for example, 20 mm or more. The continuous fiber may not have a cut surface from one end of the sheet material to the other end facing the one end. For example, one of the first sheet material 25 and the second sheet material 27 may include continuous fibers extending in one direction, and the other may include continuous fibers extending in multiple directions. For example, the first sheet material 25 may include continuous fibers extending in a plurality of directions, and the second sheet material 27 may include continuous fibers extending in one direction.

  When the first sheet material 25 or the second sheet material 27 includes carbon fibers, for example, PAN-based carbon fibers, PITCH-based carbon fibers, or the like can be used as the carbon fibers. When the first sheet material 25 or the second sheet material 27 contains glass fibers, for example, E glass fibers can be used as the glass fibers. For example, the first sheet material 25 may include continuous fibers of glass fibers extending in a plurality of directions, and the second sheet material 27 may include continuous fibers of carbon fibers extending in one direction.

  As the synthetic resin impregnated in the fibrous base material, either a thermoplastic resin or a thermosetting resin may be used, but it is preferable to use a thermoplastic resin. As the thermoplastic resin, for example, a polypropylene resin, an acrylic resin, a polyvinyl chloride resin, a polyamide resin, a polyphenylene sulfide resin, or a polyether ether ketone resin is preferable. When the first sheet material 25 and the second sheet material 27 include a thermoplastic resin, the thermoplastic resin can be softened and recovered by heating. For this reason, the recyclability of the share web 20 can be further improved. Examples of the thermosetting resin include an epoxy resin, an unsaturated polyester resin, a phenol resin, a melamine resin, and a polyurethane resin, and an unsaturated polyester resin and an epoxy resin are preferable.

  Note that one of the first sheet material 25 and the second sheet material 27 includes the fibrous base material, but the other need not include the fibrous base material. For example, the first sheet material 25 may be made of a fiber reinforced resin including a fibrous base material and a synthetic resin impregnated in the fibrous base material, and the second sheet material 27 may be made of a synthetic resin.

  As an example of a method for obtaining the first sheet material 25 or the second sheet material 27 by impregnating the fibers with the synthetic resin, when impregnating the carbon fibers with the synthetic resin, for example, laminating the carbon fibers and the synthetic resin, By raising the temperature to a temperature equal to or higher than the melting point of the synthetic resin and pressing the laminate at a high pressure, the synthetic resin can be impregnated into the carbon fibers.

  The material of the core 26 will be described. In the present embodiment, the same synthetic resin as the synthetic resin contained in the first sheet material 25 or the second sheet material 27 is used as the synthetic resin constituting the core material 26 of the first reinforcing fiber resin sheet 21. For example, a polypropylene-based resin can be used. The core 26 has, for example, a rectangular cross section.

  Next, a method of manufacturing the first reinforced fiber resin sheet 21 described above will be described. The first reinforcing fiber resin sheet 21 is produced, for example, by welding the first sheet material 25, the second sheet material 27, and the core material 26 by hot pressing. Extrusion molding or press molding can be used for the hot press.

  In the example shown in FIG. 7 as an example, the first sheet material 25, the second sheet material 27, and the core material 26 are hot-pressed in the cavity C formed between the first mold 61 and the second mold 62. By doing so, the first reinforcing fiber resin sheet 21 is obtained. In the example shown in FIG. 7, first, the first sheet material 25 is arranged, and then, a plurality of core materials 26 are arranged on the first sheet material 25. At this time, the elongated core materials 26 are arranged on the first sheet material 25 at intervals in the X direction orthogonal to the Y direction so as to extend in the Y direction.

  Next, the second sheet material 27 is arranged on the side of the core material 26 opposite to the side where the first sheet material 25 is located, with the core material 26 sandwiched between the first sheet material 25 and the second sheet material 27. Next, as shown in FIG. 7, the second sheet material 27 is bent so as to extend along the first sheet material 25 and the core material 26.

  Thereafter, with the first sheet material 25, the second sheet material 27, and the core material 26 disposed in the cavity C, the first mold 61 and the second mold 62 are closed, and the core material 26 is sandwiched therebetween. The first sheet material 25 and the second sheet material 27 are hot pressed toward each other. As a result, the first reinforcing fiber resin sheet 21 as an integral body is obtained by welding the resin.

  An example of a method for manufacturing the share web 20 shown in FIGS. 3 and 4 will be described. First, the first reinforcing fiber resin sheet 21 shown in FIGS. 5 and 6 is prepared. In the present embodiment, the first reinforcing fiber resin sheet 21 is prepared, and at the same time, an adhesive used as a material of the base sheet 28 and the adhesive layer 29 is prepared. Next, the base sheet 28 and the first reinforcing fiber resin sheet 21 are laminated. The lamination of the base sheet 28 and the first reinforcing fiber resin sheet 21 is performed such that the base sheet 28 is located on the side of the first reinforcing fiber resin sheet 21 opposite to the side having the base region 22 and the rib region 23. To do. In the present embodiment, an adhesive layer 29 is disposed on one surface of the base sheet 28, and then the first reinforcing fiber resin sheet is disposed on the side of the adhesive layer 29 opposite to the side on which the base sheet 28 is located. By arranging 21, as shown in FIGS. 3 and 4, the base sheet 28, the adhesive layer 29 and the first reinforcing fiber resin sheet 21 are laminated. After laminating the base sheet 28 and the first reinforced fiber resin sheet 21, at least the base region 22 of the first reinforced fiber resin sheet 21 is heated from the second surface 21b side. By heating, at least in the base region 22, the first reinforcing fiber resin sheet 21 is bonded to the base sheet 28, and the shear web 20 shown in FIGS. 3 and 4 can be manufactured.

(Connection part)
Next, the connecting portion 30 that connects the spur cap 13 and the share web 20 will be described. In the example shown in FIG. 2, the wind turbine blade 1 includes two connecting portions 30 that connect the first end portions 20 a of the two shear webs 20 to the inner surface 13 b of the spar cap 13 on the abdominal side, and the two shear webs 20. And two connecting portions 30 for connecting each second end portion 20b to the inner surface 13b of the back side spar cap 13. The configuration of the four connection parts 30 is substantially the same. Hereinafter, the configuration of the connection portion 30 that connects the first end portion 20a of the shear web 20 to the inner surface 13b of the abdominal spar cap 13 will be described with reference to FIG.

  FIG. 8 is a partial cross-sectional view showing an enlarged portion surrounded by a broken line denoted by reference numeral VIII in FIG. In FIG. 8, the outer surface 13a and the inner surface 13b of the spar cap 13, which are shown as curved surfaces in FIG. 2, are shown as plane surfaces for simplification of the drawing. As shown in FIG. 8, the connection section 30 according to the present embodiment includes a connection auxiliary member 31 and an adhesive 32.

  As shown in FIG. 8, the connection assisting member 31 has at least a pair of walls 311 built on the inner surface 13b side of the spar cap 13. The pair of walls 311 is provided such that the first end 20a of the share web 20 is located therebetween. The shape of the pair of wall portions 311 is not particularly limited as long as the adhesive 32 can be formed between the pair of wall portions 311. In the example shown in FIG. 8, the pair of wall portions 311 has a surface perpendicular to the inner surface 13 b of the spar cap 13. Although not shown, the pair of wall portions 311 may have a surface inclined with respect to the inner surface 13b of the spar cap 13. An interval w4 between the pair of wall portions 311 is appropriately determined according to an interval of the maximum width w3 of the share web 20. For example, w4 is 110% or more and 120% or less of w3. In this case, for example, when w3 is 30 mm, w4 is 33 mm or more and 36 mm or less.

  As shown in FIG. 8, the connection assisting member 31 is located between the first end 20 a of the shear web 20 and the inner surface 13 b of the spar cap 13, and further includes a bottom portion 312 extending along the inner surface 13 b of the spar cap 13. Have. The ends of the pair of walls 311 on the side of the spar cap 13 are connected to the bottom 312. In the example shown in FIG. 8, the bottom 312 is connected to the inner surface 13 b of the spar cap 13. For example, the bottom 312 is adhered to the inner surface 13b of the spar cap 13 with an adhesive. As the adhesive for bonding the bottom 312 to the inner surface 13b side of the spar cap 13, an adhesive containing a thermosetting resin such as an epoxy resin can be used, for example. By interposing the bottom 312 between the wall 311 and the inner surface 13b of the spar cap 13, the connection assisting member 31 and the spar cap can be compared with a case where the wall 311 is directly bonded to the inner surface 13b of the spar cap 13. 13 can have a large bonding area with the inner surface 13b.

  Preferably, as shown in FIG. 8, the bottom 312 of the connection assisting member 31 extends outside the pair of walls 311 in the direction in which the inner surface 13b of the spar cap 13 expands. Thereby, the bonding area between the connection auxiliary member 31 and the inner surface 13b of the spar cap 13 can be further increased. The width w5 of a portion of the bottom 312 located outside the pair of walls 311 is, for example, 2 cm or more and 5 cm or less.

  The material of the connection auxiliary member 31 is not particularly limited as long as the strength of the connection auxiliary member 31 can be ensured. As an example, a thermosetting resin such as an epoxy resin or an unsaturated polyester resin, or a thermoplastic resin such as a polycarbonate resin or an ABS resin can be used. When epoxy resin is used as the material of the connection auxiliary member 31, the connection auxiliary member 31 can be formed by, for example, a drawing method in which long glass fibers are combined.

  As shown in FIG. 8, the adhesive 32 according to the present embodiment is provided between a pair of walls 311 so as to be in contact with the wall 311, the bottom 312, and the shear web 20. The adhesive 32 is at least partially located between the plurality of rib regions 23 of the first reinforcing fiber resin sheet 21 of the shear web 20. As shown in FIG. 8, the adhesive 32 may be in contact with the base region 22 of the first reinforcing fiber resin sheet 21. Further, the adhesive 32 may be in contact with the side surface 24 of the rib region 23 of the first reinforcing fiber resin sheet 21.

  The material of the adhesive 32 will be described. The adhesive 32 according to the present embodiment contains a resin. The material of the adhesive according to the present embodiment is a material that is bonded to at least the material of the connection assisting member 31. As a material of the adhesive according to the present embodiment, for example, a reactive resin can be used. Here, the reactive resin is a resin which is initially liquid but can be cured by causing a curing reaction. As the reactive resin, a thermosetting resin such as an epoxy resin, an ultraviolet curable resin such as an acrylic resin, or a moisture curable resin such as a silicone resin or a modified silicone resin can be used. The adhesive 32 according to the present embodiment is more preferably a material that is bonded to the material of the shear web 20. For example, in a case where the connection auxiliary member 31 includes an epoxy resin as a material and the share web 20 includes an epoxy resin as a material, the epoxy resin is used as the adhesive 32 so that the adhesive 32 is connected to the connection auxiliary member 31 and the share web. 20 can be adhered to both.

(Connection method)
Next, an example of a connection method for forming the connection portion 30 according to the present embodiment and connecting the spur cap 13 and the share web 20 will be described. The connection method according to the present embodiment includes a connection assisting member installation step, a shear web arrangement step, a reactive resin supply step, and a reactive resin curing step.

  First, in the connection auxiliary member installation step, the connection auxiliary member 31 is provided on the inner surface 13b of the spar cap 13. In the present embodiment, the bottom 312 of the connection assisting member 31 is connected to the inner surface 13b of the spar cap 13 by, for example, bonding using an adhesive.

  Next, in the share web arranging step, as shown in FIG. 9, the connection auxiliary member 31 is positioned so that the first end 20 a of the share web 20 is located between the pair of wall portions 311 of the connection auxiliary member 31. The share web 20 is arranged.

  Next, in a reactive resin supply step, as shown in FIG. 10, the reactive resin 33 is supplied between the pair of wall portions 311. As shown in FIG. 10, the reactive resin 33 is supplied so as to be in contact with the wall portion 311 and the shear web 20 and to be at least partially located between the plurality of rib regions 23. The reactive resin 33 that can be used in the reactive resin supply step is a resin that is liquid when supplied between the walls 311 and can cause a curing reaction after the supply. Since the reactive resin 33 is in a liquid state at the time of supply, the reactive resin 33 is supplied between the wall portions 311 with the side of the connection assisting member 31 where the spar cap 13 is located down, and the rib is formed by the action of gravity. The reactive resin 33 can be supplied between the regions 23. From the viewpoint of more smoothly supplying the reactive resin 33 between the rib regions 23 by the action of gravity, it is preferable that the viscosity of the reactive resin 33 before curing is small.

  Next, in the reactive resin curing step, the reactive resin 33 supplied between the wall portions 311 is cured. Thus, as shown in FIG. 8, the adhesive 32 made of the reactive resin 33 is formed. The method of curing the reactive resin 33 is appropriately selected according to the type of the reactive resin 33. For example, when the reactive resin 33 is an epoxy resin, the reactive resin 33 is cured by heating to a temperature of 60 ° C. or more and 90 ° C. or less by a method such as a heating furnace or hot air heating. When the reactive resin 33 is moisture-cured silicone resin, the reactive resin 33 is cured by a method such as leaving indoors. By the above method, the connection portion 30 having the connection auxiliary member 31 and the adhesive 32 can be formed, and the spur cap 13 and the shear web 20 can be connected. The connection method according to the present embodiment can be applied to the manufacture of the wind turbine blade 1 shown in FIG.

  The operation and effect brought about by the connecting portion 30 according to the present embodiment will be specifically described by comparing with a comparative example.

(Comparative example)
As a comparative example, the inner surface 13b of the spar cap 13 and the first end 20a of the share web 20 are connected via an adhesive layer, for example, by applying an adhesive to the first end 20a of the share web 20. Think about the case. FIG. 11 is a cross-sectional view when the inner surface 13 b of the spar cap 13 and the first end 20 a of the shear web 20 are directly connected via the adhesive layer 34. In this case, the spread area of the adhesive layer 34 is limited to the spread area of the first end 20a of the shear web 20. For this reason, it is not possible to secure an area for bonding the spar cap 13 and the shear web 20 via the adhesive layer 34, and it is difficult to firmly connect the spar cap 13 and the shear web 20.

  On the other hand, the adhesive 32 of the connection part 30 according to the present embodiment is at least partially located between the plurality of rib regions 23 as shown in FIG. Therefore, the adhesive 32 and the shear web 20 are more firmly connected by the anchor effect. In the example shown in FIG. 8, the adhesive 32 contacts the base region 22 and the side surface 24 of the shear web 20. In this case, the area where the adhesive 32 and the shear web 20 contact each other can be increased. Thus, when the adhesive 32 is a material that is bonded to the material of the shear web 20, the area of the bonding surface between the adhesive 32 and the shear web 20 can be increased. By the above operation, the spar cap 13 and the shear web 20 can be more firmly connected via the adhesive 32.

(Modification of connection auxiliary member)
In the above-described embodiment, an example has been described in which the ends of the pair of walls 311 of the connection assisting member 31 are connected to the bottom 312, and the bottom 312 is connected to the inner surface 13b of the spar cap 13. That is, an example is shown in which the ends of the pair of walls 311 are fixed to the inner surface 13b of the spar cap 13 via the bottom 312. However, the present invention is not limited to this, and as shown in FIG. 12 or FIG. 13, even if the ends of the pair of walls 311 are fixed to the inner surface 13 b of the spar cap 13 without passing through the bottom 312. Good. In FIG. 12, the ends of the pair of walls 311 are fixed to the inner surface 13b of the spar cap 13 with an adhesive or the like. In the example shown in FIG. 13, the pair of wall portions 311 is formed of the same member as the member forming the inner surface 13 b of the spar cap 13. The pair of wall portions 311 shown in FIG. 13 can be manufactured by simultaneously molding a portion corresponding to the connection assisting member 31 when the spar cap 13 is molded.

  As shown in FIGS. 12 and 13, even when the connection assisting member 31 does not have the bottom 312, the wall 311, the inner surface 13 b of the spar cap 13, and the shear web 20 are in contact between the pair of walls 311. The adhesive 32 can be provided as described above. Further, the adhesive 32 can be positioned at least partially between the plurality of rib regions 23. For this reason, the adhesive 32 and the shear web 20 can be firmly connected by the anchor effect.

  In the example shown in FIGS. 12 and 13, the adhesive 32 is in contact with the inner surface 13 b of the spar cap 13. In this case, it is preferable that the material of the adhesive 32 has high adhesiveness to the material forming the inner surface 13b of the spar cap 13. For example, when the material forming the inner surface 13b of the spar cap 13 includes an epoxy resin, the material of the adhesive 32 preferably includes an epoxy resin.

(Modification of First Reinforcing Fiber Resin Sheet)
In the above-described embodiment and each of the modified examples, an example has been described in which the rib region 23 of the first reinforcing fiber resin sheet 21 extends in a direction orthogonal to one side of the reinforcing fiber resin sheet 10. However, the direction in which the rib region 23 of the first reinforcing fiber resin sheet 21 extends is not limited to this. FIG. 14 is a plan view showing a first reinforcing fiber resin sheet 21 according to a modified example of the first reinforcing fiber resin sheet. In FIG. 14, the first reinforcing fiber resin sheet 21 has a rectangular shape including a long side 21c extending in the direction d2. In this modification, the direction d3 in which the rib region 23 of the reinforcing fiber resin sheet 10 extends is inclined by an angle θ with respect to the direction d2 in which the long side 21c of the first reinforcing fiber resin sheet 21 extends. Is preferably 30 ° or more and less than 90 °. Angle θ is more preferably 45 °.

(First Modification of Share Web)
FIG. 15 is a perspective view showing a first modification of the share web. FIG. 16 is a cross-sectional view along the XVI-XVI direction in FIG. In the first modified example of the shear web, a reinforcing fiber resin sheet having the same components as the first reinforcing fiber resin sheet 21 is used as the base sheet 28 of the shear web 20. Hereinafter, this reinforced fiber resin sheet is also referred to as a second reinforced fiber resin sheet 41. The components of the second reinforcing fiber resin sheet 41 are represented by the same names as the corresponding components of the first reinforcing fiber resin sheet 21. Further, the description regarding the first reinforcing fiber resin sheet 21 is also applied to the second reinforcing fiber resin sheet 41 unless there is a contradiction.

  As shown in FIGS. 15 and 16, in the present modified example, the second reinforcing fiber resin sheet 41 is provided on the first surface 21 a side of the first reinforcing fiber resin sheet 21. The second reinforcing fiber resin sheet 41 has a first surface 41 a facing the first surface 21 a of the first reinforcing fiber resin sheet 21 and a second surface located on a side opposite to the first surface 41 a of the second reinforcing fiber resin sheet 41. And two surfaces 41b. In the example shown in FIG. 15 and FIG. 16, since the first surface 21 a of the first reinforcing fiber resin sheet 21 and the first surface 41 a of the second reinforcing fiber resin sheet 41 are bonded, the shear web 20 is formed. Is formed. As shown in FIGS. 15 and 16, the second surface 41 b of the second reinforcing fiber resin sheet 41 protrudes from the plurality of base regions 42 and the side away from the first surface 41 a of the second reinforcing fiber resin sheet 41. And a plurality of rib regions 43. Since the shear web 20 includes the first reinforcing fiber resin sheet 21 and the second reinforcing fiber resin sheet 41, the strength of the shear web 20 can be further improved. As shown in FIGS. 15 and 16, in this modification, the rib region 23 of the first reinforcing fiber resin sheet 21 and the rib region 43 of the second reinforcing fiber resin sheet 41 also extend in the Y direction. The shape and size of the first reinforcing fiber resin sheet 21 and the shape and size of the second reinforcing fiber resin sheet 41 may be the same or different. For example, the width of the rib region 23 of the first reinforcing fiber resin sheet 21 and the width of the rib region 23 of the second reinforcing fiber resin sheet 41 may be the same or different.

  The connection section 30 when the share web 20 according to the present modification is connected to the supercap 13 will be described. FIG. 17 is a cross-sectional view showing the connection portion 30 when the share web 20 according to the present modification is connected to the spar cap 13. In this case, as shown in FIG. 17, the adhesive 32 may be located at least partially between the plurality of rib regions 43 on the second surface 41b of the second reinforcing fiber resin sheet 41. As shown in FIG. 17, the adhesive 32 may be in contact with the base region 42 of the second reinforcing fiber resin sheet 41 or may be in contact with the side surface 44 of the second surface 41b.

(Second Modification of Share Web)
In the first modified example of the share web, the rib region 23 of the first reinforcing fiber resin sheet 21 and the rib region 43 of the second reinforcing fiber resin sheet 41 extend in the same direction as the share web 20. Was shown. However, the share web 20 is not limited to this. FIG. 18 is a perspective view showing a second modification of the share web. In the second modified example of the shear web, the rib region 23 of the first reinforcing fiber resin sheet 21 and the rib region 43 of the second reinforcing fiber resin sheet 41 extend linearly in different directions in plan view. Thereby, the strength of the share web 20 can be improved in two different directions. In the example shown in FIG. 18, the rib region 23 of the first reinforcing fiber resin sheet 21 and the rib region 43 of the second reinforcing fiber resin sheet 41 extend in directions orthogonal to each other in plan view.

DESCRIPTION OF SYMBOLS 1 Windmill blade 11 Outer skin material 13 Spar cap 13a Outer surface 13b Inner surface 17 Endothelium material 20 Share web 20a First end 20b Second end 21 First reinforced fiber resin sheet 21a First surface 21b Second surface 21c Long side 22 Base region 23 rib area 24 side surface 25 first sheet material 26 core material 27 second sheet material 28 base sheet 29 adhesive layer 30 connection part 31 connection auxiliary member 311 wall part 312 bottom part 32 adhesive material 321 insertion part 33 reactive resin 41 2 Reinforced fiber resin sheet 61 First mold 62 Second mold 80 Windmill 82 Support column 83 Nacelle 84 Rotor head

Claims (14)

A spar cap having an outer surface and an inner surface,
A connection auxiliary member having at least a pair of walls built on the inner surface side of the spar cap,
A shear web located between a pair of said wall portions and including a first end portion facing the inner surface of the spar cap and a second end portion opposite to the first end portion; A shear web having at least a first reinforcing fiber resin sheet including a first surface and a second surface extending from one end to the second end;
An adhesive containing resin, which is in contact with the wall portion and the shear web between the pair of wall portions,
The second surface of the first reinforcing fiber resin sheet has a plurality of base regions and a plurality of rib regions protruding on a side away from the first surface,
The windmill blade, wherein the adhesive is at least partially located between the plurality of rib regions. The connection assisting member further includes a bottom portion connected to an end of the pair of wall portions on the spar cap side and extending along the inner surface of the spar cap,
The wind turbine blade according to claim 1, wherein the adhesive is in contact with the wall, the bottom, and the shear web.   3. The wind turbine blade according to claim 2, wherein the bottom portion of the connection assisting member extends outward from a pair of the wall portions in a direction in which an inner surface of the spar cap expands.   The windmill blade according to any one of claims 1 to 3, wherein the plurality of rib regions of the first reinforcing fiber resin sheet extend linearly in parallel with each other.   The wind turbine blade according to any one of claims 1 to 4, wherein the first reinforcing fiber resin sheet includes a carbon fiber and a thermoplastic resin. The first reinforcing fiber resin sheet is a first sheet material, a core material that is located on one surface of the first sheet material and forms the rib region, and the first sheet material that covers the core material. And a second sheet material laminated on
The wind turbine blade according to claim 5, wherein one of the first sheet material and the second sheet material includes continuous fibers extending in one direction, and the other includes continuous fibers extending in a plurality of directions. The share web has a second reinforcing fiber resin sheet provided on a first surface side of the first reinforcing fiber resin sheet,
The second reinforcing fiber resin sheet includes a first surface facing the first surface of the first reinforcing fiber resin sheet, and a second surface located on a side opposite to the first surface of the second reinforcing fiber resin sheet. Surface and
The second surface of the second reinforcing fiber resin sheet has a plurality of the base regions, and a plurality of the rib regions protruding to a side away from the first surface of the second reinforcing fiber resin sheet,
The wind turbine blade according to any one of claims 1 to 6, wherein the adhesive is at least partially located between the plurality of rib regions on the second surface of the second reinforcing fiber resin sheet. The first end of the shear web including a first end facing the inner surface and a second end opposite the first end is connected to the inner surface of the spar cap having an outer surface and an inner surface. Connection part,
The shear web has at least a first reinforcing fiber resin sheet including a first surface and a second surface extending from the first end to the second end,
The second surface of the first reinforcing fiber resin sheet has a plurality of base regions and a plurality of rib regions protruding on a side away from the first surface,
The connection part has at least a pair of walls built on the inner surface side of the spar cap such that the first end of the shear web is located therebetween, a connection auxiliary member,
An adhesive containing resin, which is in contact with the wall portion and the shear web between the pair of wall portions,
A connection, wherein the adhesive is at least partially located between the plurality of rib regions; The connection assisting member further includes a bottom portion connected to an end of the pair of wall portions on the spar cap side and extending along the inner surface of the spar cap,
9. The connection according to claim 8, wherein the adhesive is in contact with the wall, the bottom, and the shear web.   The connection part according to claim 9, wherein the bottom part of the connection auxiliary member extends to an outside of a pair of the wall parts in a direction in which an inner surface of the spar cap expands. The share web has a second reinforcing fiber resin sheet provided on a first surface side of the first reinforcing fiber resin sheet,
The second reinforcing fiber resin sheet includes a first surface facing the first surface of the first reinforcing fiber resin sheet, and a second surface located on a side opposite to the first surface of the second reinforcing fiber resin sheet. Surface and
The second surface of the second reinforcing fiber resin sheet has a plurality of the base regions, and a plurality of the rib regions protruding to a side away from the first surface of the second reinforcing fiber resin sheet,
The connection part according to any one of claims 8 to 10, wherein the adhesive is at least partially located between the plurality of rib regions on the second surface of the second reinforcing fiber resin sheet. The first end of the shear web including a first end facing the inner surface and a second end opposite the first end is connected to the inner surface of the spar cap having an outer surface and an inner surface. Connection method,
The shear web has at least a first reinforcing fiber resin sheet including a first surface and a second surface extending from the first end to the second end,
The second surface of the first reinforcing fiber resin sheet has a plurality of base regions and a plurality of rib regions protruding on a side away from the first surface,
The connection method,
A connection auxiliary member installation step of providing a connection auxiliary member having at least a pair of walls on the inner surface of the spar cap,
A share web arranging step of arranging the share web such that the first end of the share web is located between the pair of wall portions;
Supplying a reactive resin between a pair of the wall portions so as to be in contact with the wall portion and the shear web and at least partially located between the plurality of rib regions; Process and
A reactive resin curing step of curing the reactive resin.   The connection method according to claim 12, wherein the reactive resin is a thermosetting resin, an ultraviolet curable resin, or a moisture curable resin.   A method for manufacturing a wind turbine blade, comprising the connection method according to claim 12.