JP4561344B2 - Wing member - Google Patents

Description

  The present invention relates to an FRP blade member suitable for a wind power generation blade and the like, and a method for manufacturing the same.

  The wing member has a shape in which the cross section has a thickness distribution, thereby expressing the function of controlling the flow of fluid. Generally used for horizontal wings and vertical wings typified by rear spoilers for aircraft and automobiles, propeller wings for aircraft, helicopters and ships, turbine blades for blowers, blades for agitators, blades for wind power generation, and the like. As in these examples, the wing member is often used while being fixed to a moving body or by rotating itself so as to control the flow of fluid.

  Therefore, the wing member is required to be lightweight. That is, it contributes to lightening of the structure and power of the apparatus by reducing the weight of the entire apparatus including the wing member and reducing the inertial force of the wing member.

  Further, since the wing member receives pressure from the fluid, it is indispensable to have sufficient strength and rigidity that can withstand destruction and deformation.

  Conventionally, metal materials such as aluminum and titanium have been used as wing members, but fiber reinforced resin (hereinafter referred to as FRP) that is lighter in weight, higher in strength, and higher in rigidity than metal due to the demand for light weight and high rigidity. Is abbreviated). Furthermore, in recent years, in order to achieve further weight reduction while ensuring high strength and high rigidity, a sandwich structure in which a low density resin or honeycomb structure is filled as a core material surrounded by the FRP skin material and the skin material. Proposed.

  For example, Patent Document 1 describes a rear spoiler for an automobile in which a foam core is disposed on a hollow main body made of FRP. Patent Document 2 describes a wind turbine blade in which a foam filler reinforced with glass fiber is filled in a fiber reinforced resin outer skin. Although it is important for the wing member to increase the strength and rigidity in the longitudinal direction from the purpose of use, none of these documents recognizes this point as a problem, and no effective solution has been proposed.

  In order to solve this problem, Patent Document 3 discloses a propeller for a wind power generator characterized in that a main girder is arranged inside a blade surrounded by a skin layer made of reinforced resin, and fibers are continuous on the front edge side. Suggest a blade. In this propeller blade, the main girder is arranged inside the blade, so that the strength and rigidity in the longitudinal direction of the blade itself are improved. On the other hand, it cannot be said that sufficient consideration is given to lightness, which is a necessary characteristic.

In addition, when the blade is composed of a plurality of structures made up of a main girder, front and rear reinforcements, etc., the strength and rigidity as a member cannot be obtained unless the joint strength between them is high, and the degree of difficulty in applying the technology is reduced. Cost increases cannot be ignored due to the high cost and the extra man-hours required to place multiple structures.
JP 2004-268875 A JP-A-6-323238 JP-A No. 13-165033

    An object of the present invention is to provide a highly efficient and safe wing member that achieves light weight, high strength, and high rigidity in view of the drawbacks of the prior art.

The present invention employs the following means in order to solve such problems. That is,
(1) A wing member [1] including the following components [A] and [B], wherein the component [A] completely includes [B ] .

[A] Skin material [2] made of FRP including continuous carbon fiber layers aligned in the longitudinal direction over 90% or more of the total length of the wing member [1 ]
[B] The density is 0.05 to 1.0 g / cm ³ , and the density of the constituent element [B] in the portion having a thickness of 3 mm or less is in the range of 1.5 to 10 times the average density of [B] as a whole. The core material [3] consisting of a porous resin body having a monolithic structure

( 2 ) Wing member [1] as described in (1 ) whose thickness of component [A] exists in the range of 0.5-5.0 mm.

( 3 ) The maximum thickness at the leading edge [4] of the component [A] is in the range of 1.05 to 5 times the average thickness of the entire component [A] (1) or (2) Wing member [1] described.

( 4 ) The wing member [1] according to any one of (1) to ( 3 ), wherein a ratio W / L of the total width W (m) to the total length L (m) is 0.05 to 0.5.

( 5 ) The wing member [1] according to any one of (1) to ( 4 ), wherein the component [A] and the component [B] are integrated.

( 6 ) The blade member [1] according to any one of (1) to ( 5 ), wherein a primary natural frequency in free vibration is in a range of 20 to 100 Hz.

( 7 ) The wing member [1] according to any one of (1) to ( 6 ), which is a blade for wind power generation.

( 8 ) A method for manufacturing a wing member [1] including the following components [A] and [B], wherein the component [B] is short in an arbitrary cross section perpendicular to the longitudinal direction of the wing member [1]. The ratio D ₁ / D ₂ between the length D ₁ (m) of the diameter and the length D ₂ (m) of the minor axis of the component [B] before being included in the component [A] is 0.2. A method for producing a wing member [1] , wherein the pressure and pressure molding is performed by a molding method selected from the group consisting of a hot press, an autoclave, and an RTM so as to be within a range of ˜0.95.

[A] Skin material [2] made of FRP including continuous carbon fiber layers aligned in the longitudinal direction over 90% or more of the total length of the wing member [1 ]
[B] The density is 0.05 to 1.0 g / cm ³ , and the density of the constituent element [B] in the portion having a thickness of 3 mm or less is in the range of 1.5 to 10 times the average density of [B] as a whole. The core material [3] consisting of a porous resin body having a monolithic structure
( 9 ) The method for producing the wing member [1] according to ( 8 ), wherein the component [B] is obtained by injecting a liquid resin into the wing member [1] -shaped mold and then foaming and curing in the mold.

(1 0 ) Wrapping member according to ( 8 ) or ( 9 ), in which a fiber reinforced prepreg sheet is completely wrapped around the component [B] to obtain a laminated body before heating and pressing . 1] .

According to the wing member of the present invention, it is possible to provide a wing member that is lightweight and has high strength and high rigidity against tension and bending in the longitudinal direction.

  The present invention will be described below with reference to the drawings. FIG. 1 is an overall perspective view of a wing member. 2 is a cross-sectional view taken along the line aa in FIG. 1, and FIG. 3 is a cross-sectional view taken along the line bb in FIG. 1. As shown in FIGS. The resin porous body is completely included.

  In order to efficiently improve the rigidity of the blade structure and reduce the weight, it is preferable to enhance the rigidity of the outer skin. In the present invention, high strength and high rigidity are obtained by using FRP for the skin material 2, and further, the core material 3 is completely included in the skin material 2, thereby preventing moisture and foreign matter from entering the wing member. In addition, since the stress concentration can be reduced, the durability of the wing member can be improved. From this point of view, as FRP, carbon fiber, glass fiber, organic high modulus fiber (for example, polyaramid fiber “Kevlar” manufactured by DuPont, USA), alumina fiber, silicon carbide fiber, boron are used as the reinforcing fiber. High strength and high elastic modulus fibers such as fibers and silicon carbide fibers are preferred. Further, synthetic fibers such as polyamide fibers, polyester fibers, acrylic fibers, polyolefin fibers, vinylon fibers, and organic natural fibers can also be used, and these reinforcing fibers may be used alone or in combination. Among these, in order to achieve at least both high rigidity and light weight, it is necessary to include carbon fiber having a high specific elastic modulus, which is a ratio of elastic modulus and density. As the carbon fiber, for example, polyacrylonitrile (PAN-based), pitch-based, cellulose-based, vapor-grown carbon fiber by hydrocarbon, graphite fiber, or the like can be used, and two or more of these may be used in combination. Among these, it is preferable to include a PAN-based carbon fiber that has an excellent balance between strength and rigidity. Further, the reinforcing fiber form may be continuous fiber or discontinuous fiber, and both may be combined, but among them, carbon fiber and woven fabric aligned in one direction are more preferable.

  FIG. 3 is a cross-sectional view taken along the line bb of FIG. 1. In FIG. 3, the FRP includes a continuous carbon fiber layer 6 aligned in the longitudinal direction over at least 90% of the total length of the wing member 1. It is necessary to include a skin material 2 made of This makes it possible to achieve both lightness and strength and rigidity against tensile and bending in the longitudinal direction. When there is no layer in which continuous carbon fibers are aligned in the longitudinal direction, sufficient strength and rigidity against tension and bending cannot be obtained in the longitudinal direction of the wing member, and the wing member is subjected to a large fluid pressure. There is a possibility that problems such as large deformation and eventually destruction will occur. In particular, when the blade member is used for a wind power generation blade or the like, if the bending rigidity in the longitudinal direction is not sufficient when the blade rotates, the blade rotates while being largely deformed by the wind pressure, which reduces the power generation efficiency. Invite.

The continuous carbon fiber layer 6 may be disposed on the outermost layer of the skin material 2 and may be disposed on the innermost layer, but is preferably disposed at least other than the outermost layer so as not to be directly subjected to external impact. It is good. Further, if high bending rigidity cannot be obtained, a sufficiently high natural frequency cannot be obtained, and the FRP matrix used for the skin material 2 may resonate with the vibration of the structure in contact with the wing member and possibly destroy the wing member. As the resin, a thermosetting resin or a thermoplastic resin can be used. Specific examples include epoxy resins, phenol resins, unsaturated polyester resins, vinyl ester resins, ABS resins, polyethylene terephthalate resins, nylon resins, cyanate resins, benzoxazine resins, maleimide resins, polyimide resins, etc. It is not particularly limited. A resin that is cured with heat or an external energy such as light or electron beam with a thermosetting resin such as an epoxy resin to form a three-dimensional cured product at least partially can be preferably used. The core material 3 needs to be made of a porous resin body in order to ensure lightness. The porous resin body has a structure in which the main component is made of resin and a large number of voids are provided inside the structure. The void may be a foamed foaming agent, or a syntactic core containing many hollow glass beads. As the resin, a thermosetting resin, a thermoplastic resin, or the like can be used.For example, as the thermosetting resin, there are an epoxy resin, a phenol resin, an unsaturated polyester resin, a vinyl ester resin, and the like. Polyamide resin, modified phenylene ether resin, polyacetal resin, polyphenylene sulfide resin, polyester resin such as liquid crystal polyester, polyethylene terephthalate, polybutylene terephthalate, polycyclohexanedimethyl terephthalate, polyarylate resin, polycarbonate resin, polystyrene resin, HIPS resin, ABS resin, AES resin, styrene resin such as AAS resin, acrylic resin such as polymethyl methacrylate resin, polyolefin resin such as vinyl chloride, polyethylene, polypropylene, etc. Olefin resins, polyurethane resins, imide resins such as polyetherimide and polymethacrylimide, ethylene / propylene copolymers, ethylene / 1-butene copolymers, ethylene / propylene / diene copolymers, ethylene / carbon monoxide / Diene copolymer, ethylene / glycidyl (meth) acrylate, ethylene / vinyl acetate / glycidyl (meth) acrylate copolymer, polyether ester elastomer, polyether ether elastomer, polyether ester amide elastomer, polyester amide elastomer, There are various elastomers such as polyester ester elastomers. These may be used alone or in combination. More specifically, the core material 3 preferably uses a resin porous body having an integrated structure with a density of 0.05 to 1.0 g / cm ³ in order to ensure lightness. Here, the integral structure means a state in which the resin porous body is not divided and the resin portion is continuous both physically (formally) and chemically (composition) over the entire core material 3. Here, the density of the resin porous body and the core material is an apparent mass per volume, and greatly depends on the total volume of voids inside the structure. The density of the core material 3 needs to be 0.05 to 1.0 g / cm ³ . If it is less than 0.05, sufficient compression rigidity cannot be achieved, and there is a problem that the wing member is liable to buckle against bending load. On the other hand, when the density of the core material 3 is larger than 1.0 g / cm ³ , the compression rigidity can be sufficiently secured, but the weight increases, which is not preferable. Further, if the resin pore body does not have an integral structure, the strength of the wing member that is a molded body cannot be sufficiently obtained, which is not preferable.

In the wing member, the density of the core material 3 is required to be 1.5 to 10 times the average density of the entire core material 3 at a portion having a thickness of 3 mm or less. This is because by setting the density to 1.5 times or more, it is possible to prevent the occurrence of cracks and cracks in a thin portion where strength and rigidity tend to be insufficient due to the structure of the wing member. However, if it is larger than 10 times, the effect of reducing the weight, which is the original purpose of using the core material, is not preferable.

  As the FRP used for the skin material 2, it is preferable to use a prepreg obtained by impregnating the reinforcing fiber with the matrix resin in advance.

  The orientation of the reinforcing fibers when laminating a plurality of layers may be in the same direction in each layer, but it is more preferred to laminate at different orientation angles in order to maintain a balance of strength and rigidity in each direction as a wing member.

  The thickness of the skin material 2 is preferably in the range of 0.5 to 5.0 mm in consideration of the balance between strength, rigidity and weight reduction. If the thickness of the skin material 2 is in this range, it is preferable because the range in which the structural characteristics such as the lightening effect and the strength / rigidity can be compatible is wide and the degree of freedom in design is high. Here, the thickness of the skin material 2 typically means the thickness of the layer indicated by 7 in FIG. 4. Generally, the wing structure itself is thin at the front end and the rear edge portion 5 in the longitudinal direction. There is also a portion composed only of the material 2. In such a case, as shown in FIG. 5, the thickness 7 of the skin material may be the same as the thickness of the wing structure itself.

Moreover, since the front edge part 4 of a wing member receives a big pressure from a fluid, or receives an impact by the solid in a fluid, it is preferable that especially intensity | strength and rigidity are high. Therefore, as shown in FIG. 4, it is preferable that the maximum thickness at the front edge portion 4 of the skin material 2 is in a range of 1.05 to 5 times the average thickness of the entire skin material 2. The ratio W / L between W (m) and the total length L (m) is preferably 0.05 to 0.5. If the ratio exceeds 0.5, the bending strength and rigidity in the longitudinal direction can be afforded, but the efficiency of controlling the fluid is reduced. In general, when the ratio is 0.5 or less, there is a concern about insufficient bending strength and rigidity in the longitudinal direction due to its shape, but in the present invention, the skin material 2 is continuously aligned in the longitudinal direction. This is because there is no such problem because the carbon fiber layer 4 is provided, and the advantage of improving the efficiency of controlling the fluid is greater. In order to reduce the weight, W / L is preferably as small as possible, but is preferably 0.05 or more in view of the balance between bending strength, rigidity, and efficiency.

  Furthermore, it is preferable that the skin material 2 and the core material 3 are integrated. Although the core material 3 is composed of a low-density resin porous body, the strength and rigidity of the single body can hardly be expected. This is because it becomes an out-of-plane compression reinforcing material as a structure, improves the secondary moment of section of the wing member, and plays a major role as a bending rigidity reinforcing material.

  In addition, the natural frequency depends on the bending rigidity and weight of the material, the bending rigidity is high, and the natural frequency tends to increase as the weight decreases. When the natural frequency is small, the blade member resonates with the vibration of the structure in contact with the blade member, or the blade member generates self-excited vibration due to the viscosity of the fluid to be controlled. Therefore, it is preferable to have a high natural frequency with respect to usage conditions such as the frequency of the structure and the number of rotations. Specifically, the primary natural frequency at free vibration is preferably in the range of 20 to 100 Hz.

As a method for manufacturing the wing member, various molding methods can be applied. In particular, as shown in FIG. 6, the length D ₁ of the short diameter of the core material 3 in an arbitrary cross section perpendicular to the longitudinal direction. The ratio D ₁ / D ₂ between (m) and the length D ₂ (m) of the minor axis of the core material 3 before being included in the skin material ₂ is in the range of 0.2 to 0.95. Furthermore, it is more preferable to perform heat and pressure molding by a molding method selected from the group consisting of a hot press, an autoclave, and RTM. The minor axis means an outer diameter that is perpendicular to the major axis when the outer diameter connecting the front edge 4 and the rear edge 5 is a major axis in the cross section. Since the internal pressure from the core material 3 is obtained at the time of pressure molding by performing heat and pressure molding so that the minor axis is reduced at an appropriate ratio as compared with before being included in the skin material, the wing member It is easy to obtain a good appearance. Further, by adjusting D ₁ / D ₂ , in the wing member, it is easy to adjust the density of the core material 3 in a portion having a thickness of 3 mm or less to 1.5 to 10 times the average density of the entire core material 3. Since it can do, it is preferable also from the surface of the strength improvement of the thin part of a wing | blade member.

  More preferably, the core material 3 is obtained by injecting a liquid resin into a wing member-shaped mold and then foaming and curing in the mold. This is because the core material 3 can be obtained in a much shorter time and at a lower cost than when a desired core material 3 shape is obtained by cutting a resin foam such as a block prepared by machining or the like. It becomes possible. In addition, thin-walled shapes and three-dimensional curved surfaces that are difficult to form by machining or the like can be obtained relatively easily by using a mold having a cavity having a desired shape according to this method.

  Still more preferably, a fiber reinforced prepreg sheet is wound around the core material 3 and completely included, thereby obtaining a laminate before heating and pressing. This is because the roving of the reinforcing fiber impregnated with the thermosetting resin is wound around the core material 3 and then heated and pressed, or the reinforcing fiber fabric is wound around the core material 3 and then impregnated with the resin. Compared with the case of heating and pressing, the orientation accuracy of the reinforcing fibers is high, and the fiber-reinforced prepreg sheet is sufficiently impregnated with the resin in advance, so that it is easy to completely include the core material 3. This is effective for reducing the variation in the weight of the wing member after molding, and it is generally easy to set the fiber weight content of FRP contained in the skin material 2 to be light, high strength and high rigidity. Can be achieved.

  The wing member of the present invention can be applied not only to blades for wind power generation but also to horizontal wings of aircraft and automobile spoilers, aircraft, helicopters and ship propellers, but the application range is limited to these. is not.

It is a perspective view which shows the wing | blade member which concerns on one embodiment of this invention. It is sectional drawing which shows the aa cross section of FIG. It is sectional drawing which shows the bb cross section of FIG. It is a partial expanded sectional view of the front edge part of the wing | blade member which concerns on one embodiment of this invention. It is a partial expanded sectional view of the rear edge part of the wing | blade member which concerns on one embodiment of this invention. It is sectional drawing which shows the manufacturing method of the wing | blade member which concerns on one embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Wing member 2 Skin material 3 Core material 4 Front edge part 5 Rear edge part 6 Continuous carbon fiber layer 7 Skin material thickness

Claims (10)

A wing member [1] including the following components [A] and [B], wherein the component [A] completely includes [B ] .
[A] Skin material [2] made of FRP including continuous carbon fiber layers aligned in the longitudinal direction over 90% or more of the total length of the wing member [1 ]
[B] The density is 0.05 to 1.0 g / cm ³ , and the density of the constituent element [B] in the portion having a thickness of 3 mm or less is in the range of 1.5 to 10 times the average density of [B] as a whole. The core material [3] consisting of a porous resin body having a monolithic structure The wing member [1] according to claim 1, wherein the thickness of the constituent element [A] is in the range of 0.5 to 5.0 mm. The wing member according to claim 1 or 2 , wherein the maximum thickness at the leading edge [4] of the component [A] is within a range of 1.05 to 5 times the average thickness of the entire component [A] . 1] . The wing member [1] according to any one of claims 1 to 3 , wherein a ratio W / L of the total width W (m) to the total length L (m) is 0.05 to 0.5. The wing member [1] according to any one of claims 1 to 4 , wherein the component [A] and the component [B] are integrated. The wing member [1] according to any one of claims 1 to 5 , wherein a primary natural frequency in free vibration is in a range of 20 to 100 Hz. The blade member [1] according to any one of claims 1 to 6 , wherein the blade member is a blade for wind power generation. A method for manufacturing a wing member [1] including the following constituent elements [A] and [B], wherein the length of the minor axis of the constituent element [B] is an arbitrary cross section perpendicular to the longitudinal direction of the wing member [1]. It is _D 1 and (m), component ratio _D 1 / _{D 2} of the length of the minor component [B] before being included in [a] _D 2 (m) is from 0.2 to 0. 95. A method for producing a wing member [1] , wherein the pressure and pressure molding is performed by a molding method selected from the group consisting of hot press, autoclave, and RTM so as to be within a range of 95.
[A] Skin material [2] made of FRP including continuous carbon fiber layers aligned in the longitudinal direction over 90% or more of the total length of the wing member [1 ]
[B] The density is 0.05 to 1.0 g / cm ³ , and the density of the constituent element [B] in the portion having a thickness of 3 mm or less is in the range of 1.5 to 10 times the average density of [B] as a whole. The core material [3] consisting of a porous resin body having a monolithic structure The method for producing a wing member [1] according to claim 8 , wherein the constituent element [B] is obtained by injecting a liquid resin into the wing member [1] -shaped mold and then foaming and curing in the mold. The method for producing a wing member [1] according to claim 8 or 9 , wherein the fiber reinforced prepreg sheet is completely wrapped around the component [B] to obtain a laminated body before heating and pressing.

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