JP5427807B2 - Reinforced plastic structure, method for producing reinforced plastic structure, structure, windmill blade and windmill - Google Patents

Description

  The present invention relates to a reinforced plastic structure having a laminated structure, a method for manufacturing a reinforced plastic structure, a structure, a windmill blade, and a windmill.

  The wind turbine blade used in the wind turbine generator is formed in a planar shape along the outer skin that covers the outer peripheral surface and forms an aerodynamic shape, a spar of a strength member provided inside the outer skin, a spar cap that connects the spar, and the inner surface of the outer skin. It consists of a core material that is provided and plays a role of preventing buckling of the blade. The core material of the wind turbine blade has a large area and is generally configured by arranging a plurality of balsa plywood materials. Patent Document 1 discloses an FRP (Fiber Reinforced Plastic) structure and a method for manufacturing the same, and a technique capable of increasing the size of the structure.

Japanese Patent Laid-Open No. 11-254666

  Although the balsa plywood may be used as the core material of the windmill blade, the maximum size of the balsa plywood is limited by the plywood manufacturing apparatus. For example, when the maximum size of the balsa plywood is 1,200 mm × 600 mm, in order to form the core material of the windmill blade, as shown in FIG. 8, reinforcing fibers such as glass fiber and carbon fiber forming the outer skin 31 are used. Further, it is necessary to arrange the balsa plywood 32 in the longitudinal direction of the windmill blade 30 at a pitch of 600 mm which is the maximum width of the balsa plywood. The windmill blade 30 has, for example, a total length of 50 m. In this case, a large number of balsa plywood materials 32 are arranged.

  The arranged balsa plywood members 32 are not fixed and can move independently, and the blade shape is not a simple plane but a curved shape. And the reinforcing fibers constituting the outer skin of the wind turbine blade of the FRP in contact with the joint 33 are likely to wrinkle. And since the wrinkle of a reinforced fiber becomes a factor of a strength fall, you must pay sufficient attention to the installation precision of the balsa plywood 32.

  Therefore, the laminating work of the balsa plywood 32 is a process with many man-hours in the manufacturing process, and it is difficult to simplify the work from the viewpoint of quality, and becomes a bottleneck in shortening the production cycle. ing.

  The present invention has been made in view of such circumstances, and a reinforced plastic structure and a reinforced plastic that are not easily displaced due to independent movement of members and can be easily installed at an installation location. An object of the present invention is to provide a structure manufacturing method, a structure, a windmill blade, and a windmill.

In order to solve the above problems, the reinforced plastic structure, the manufacturing method of the reinforced plastic structure, the structure, the windmill blade, and the windmill of the present invention employ the following means.
That is, the reinforced plastic structure according to the present invention includes a plate-shaped synthetic resin material having a plurality of cuts formed in the thickness direction from one surface side, and a sheet material attached to the other surface side of the synthetic resin material. A plurality of layer members are stacked.

  According to this invention, the several layer member is laminated | stacked, and each layer member consists of a synthetic resin material and a sheet material. Thereby, a synthetic resin material and a sheet material are arrange | positioned alternately, and a strong structural body can be obtained. In the plate-shaped synthetic resin material of the layer member, a cut is formed in the thickness direction from one surface side, and a sheet material is attached to the other surface side. Therefore, the layer member can be bent along the cut line and can be arranged along a curved mold. When the plurality of cut lines are formed in parallel to each other, the layer member can be wound, so that even a member that is long in one direction can be easily loaded and unloaded.

  Further, since the layer member is made of a synthetic resin material or a sheet material, it can be easily made into a single member that is long in one direction, and members having limited sizes (for example, balsa plywood materials) are arranged in a planar shape. There is no problem of misalignment that sometimes occurs. Furthermore, even if the synthetic resin material is divided into a plurality of blocks due to the breaks, since the individual blocks are connected by the sheet material, the layer members can be handled as one continuous member, improving the installation accuracy. Can be made. The sheet material is a fabric made of, for example, fibers. In this case, the structure is a fiber-reinforced plastic structure.

  In the above invention, the cut may be wider on the one surface side of the synthetic resin material than on the other surface side.

  According to this invention, since the cross section has a wedge shape or a trapezoidal shape, for example, it is easy to bend the cut line so as to be convex with respect to the surface direction of the sheet material and to follow the curved surface shape. Become. Further, the synthetic resin can easily flow into the cut line, and the resin injection piping laid inside the structure can be reduced.

  The method for producing a reinforced plastic structure according to the present invention includes a step of forming a plurality of cuts in a thickness direction from one side to a plate-like synthetic resin material, and a sheet material is attached to the other surface side of the synthetic resin material. And a step of laminating a synthetic resin material and a layer member having the sheet member.

  According to this invention, the several layer member is laminated | stacked and each layer member manufactures the reinforced plastic structure which consists of a synthetic resin material and a sheet material. The layer member of this structure can be bent along the cut and can be placed along a curved mold. In addition, if the synthetic resin material is a single member that is long in one direction, there is no problem of misalignment that occurs when members of limited size (for example, balsa plywood materials) are arranged in a planar shape. Furthermore, even if the synthetic resin material is divided into a plurality of blocks due to the breaks, since the individual blocks are connected by the sheet material, the layer members can be handled as one continuous member, improving the installation accuracy. Can be made.

  Moreover, the structure according to the present invention includes a layer member having a plate-like core material having a plurality of cuts formed in the thickness direction from one surface side, and a sheet material attached to the other surface side of the core material. A plurality of layer members are provided.

  According to this invention, the several layer member is laminated | stacked, and each layer member consists of a core material and a sheet | seat material. Thereby, a core material and a sheet | seat material are arrange | positioned alternately, and a strong structural body can be obtained. In the plate-like core material of the layer member, a cut is formed in the thickness direction from one surface side, and a sheet material is attached to the other surface side. Therefore, the layer member can be bent along the cut line, and can be arranged along a curved mold. When a plurality of cuts are formed in parallel to each other, the layer member can be wound, so that even a member that is long in one direction can be easily carried in and out.

  In addition, even if the core material is divided into a plurality of blocks due to the cuts, since the individual blocks are connected by the sheet material, the layer member can be handled as a single continuous member, and the installation accuracy is improved. be able to. Furthermore, since the individual blocks of the core material are connected to the sheet material, there is no problem of displacement that occurs when blocks that are not joined to the sheet material are arranged in a planar shape. When the core material is a synthetic resin material and the sheet material is a fabric made of fibers, the structure is a fiber-reinforced plastic structure. The core material may be wood such as balsa synthetic material.

Moreover, the windmill blade which concerns on this invention is equipped with said reinforced plastic structure or said structure. Furthermore, the windmill which concerns on this invention is equipped with said windmill blade.
According to these inventions, by providing the reinforced plastic structure or structure described above, it is possible to easily manufacture a windmill blade or a windmill, and the reinforced plastic structure or structure made of a member having a limited size. It is possible to avoid a decrease in strength as compared with the case where is used.

  According to the present invention, the reinforced plastic structure and the structure are less likely to be displaced due to independent movement of the members, and can be easily installed at the installation location.

It is a perspective view which shows the FRP structure which concerns on one Embodiment of this invention. FIG. 2 is a partially enlarged perspective view of FIG. 1. It is a top view which shows the windmill blade which installed the FRP structure as a core material. It is sectional drawing cut | disconnected by the AA line of FIG. It is a side view which shows the winding-up state of a FRP structure. It is a side view which shows the 1st modification of the FRP structure which concerns on one Embodiment of this invention. It is a side view which shows the core material which uses the 2nd modification of the FRP structure which concerns on one Embodiment of this invention. It is a top view which shows the windmill blade which installed the balsa plywood material as a core material.

Embodiments according to the present invention will be described below with reference to the drawings.
First, the configuration of an FRP (Fiber Reinforced Plastics) structure 1 according to an embodiment of the present invention will be described with reference to FIGS.

  As shown in FIGS. 3 and 4, the FRP structure 1 according to the present embodiment is used, for example, as a core material of a wind turbine blade 10 of a wind turbine generator. The core material is provided along the outer skin 11 of the windmill blade 10 and is installed long along the longitudinal direction of the windmill blade 10.

  The FRP structure 1 is formed by laminating a plurality of layer members, and each layer member includes a synthetic resin material 2 and a sheet material 4. In the FRP structure 1, the synthetic resin material 2 and the sheet material 4 are alternately arranged, and a high strength structure can be obtained.

  The synthetic resin material 2 is a plate-like member, for example, a foam material. As shown in FIG. 2, the synthetic resin material 2 may be provided with a through hole 7 penetrating in the thickness direction. When the synthetic resin material 2 is used as a core material of the wind turbine blade 10, it is desirable that the synthetic resin material 2 is a foamed material having a closed cell structure. That is, in the formation of FRP by the VaRTM (Vacuum Assisted Resin Transfer Molding) method, the core material portion of the wind turbine blade 10 has a through hole 7 in the thickness direction and a flow path (not shown) parallel to the in-plane direction. Are provided, and a base material resin (matrix resin) such as an epoxy resin is impregnated in the reinforcing fibers around the core material. However, it is not desirable from the viewpoint of weight increase that the base material resin permeates other than the through holes 7 and the flow paths of the synthetic resin material 2 and the whole core material is filled with the base material resin. Therefore, a foam material with a closed cell structure is desirable instead of a foam material with an open cell structure.

  The synthetic resin material 2 is made of a synthetic resin such as PVC (polyvinyl chloride) or PET (polyethylene terephthalate). In addition, although this specification demonstrated the case where the member affixed on the sheet material 4 is the synthetic resin material 2, this invention is not limited to this example. For example, wood such as balsa plywood may be used.

  A cut 3 is formed in the synthetic resin material 2 in the thickness direction from one surface side. For example, as shown in FIGS. 1 and 2, the cuts 3 are provided in a lattice shape, and a plurality of cuts 3 parallel to one direction (for example, the longitudinal direction of the FRP structure 1) and a direction perpendicular to the one direction ( For example, it consists of a plurality of cuts 3 in the width direction of the FRP structure 1. The width of the cut 3 shown in FIGS. 1 and 2 is constant in the thickness direction. By providing the cut 3, the FRP structure 1 can be arranged to follow the curved shape of the mold 20. Also, the size of the grid need not be constant. For example, in the mold where the FRP structure 1 is disposed, the lattice may be reduced in a portion where the curvature is large, and the lattice may be increased in a portion where the curvature is small.

  The sheet material 4 is a fabric made of fibers such as glass fiber, polyester fiber, and nylon fiber. The sheet material 4 may be a material into which the liquid base resin material can permeate, and the strength of the FRP structure 1 is increased by curing the permeated synthetic resin material. The sheet material 4 is attached to the surface of the synthetic resin material 2 opposite to the surface on which the cuts 3 are formed, for example, with an adhesive. The sheet material 4 is affixed to the synthetic resin material 2 so that all the synthetic resin materials 2 divided into a plurality of blocks by the cuts 3 are connected.

  The layer member made of the synthetic resin material 2 and the sheet material 4 can be bent along the cut line 3, and the layer member can be arranged along a curved surface mold or the like. In addition, when the plurality of cuts 3 are formed in parallel to each other, the layer member can be wound up as shown in FIG. 5, so that it is easy to carry in and out even if the layer member is a member that is long in one direction. It is.

  In addition, the layer member can be easily formed into a single member that is long in one direction, particularly when composed of the synthetic resin material 2 or the sheet material 4, and a member having a limited size (for example, a balsa plywood material). There is no problem of misalignment that occurs when the are arranged in a plane. Further, even if the synthetic resin material 2 is divided into a plurality of blocks by the cuts 3, since the individual blocks are connected to the sheet material 4, when the blocks not joined to the sheet material 4 are arranged in a planar shape There is no problem of displacement, and the layer member can be handled as one continuous member, and the installation accuracy can be improved.

Next, a modification of this embodiment will be described.
The width of the cut 3 shown in FIGS. 1 and 2 is constant in the thickness direction, but the present invention is not limited to this example. As shown in FIG. 6, the width of the cut 5 changes from one side of the synthetic resin material 2 to the other side, and the width of the one side of the synthetic resin material 2 is wider than the other side, The cross section may be, for example, a wedge shape or a trapezoidal shape. Further, as shown in FIG. 7, the width of the cut 6 is changed from one surface side of the synthetic resin material 2 to the middle of the thickness direction, and thereafter a cut 3 having a constant width is formed. Also good. By providing the cut lines 5 and 6, the FRP structure 1 can be bent so that the side on which the sheet material 4 is provided is convex, and the FRP structure 1 can be arranged to follow the curved shape of the mold 20. It becomes easy.

  In addition, since the cross sections of the cuts 5 and 6 are, for example, wedge-shaped or trapezoidal, the base resin easily flows into the cuts 5 and 6. Therefore, the cuts 5 and 6 serve as a resin injection flow path, and the number of resin injection pipes conventionally laid on the top of the product can be reduced. Further, as shown in FIG. 7, since a resin injection flow path is formed by the cut line 6 in a plurality of layers (second layer and third layer), the amount of inflowing resin can be increased, which is effective. The resin can be impregnated into the reinforcing fibers around the core material. Here, the layer in contact with the reinforcing fiber that forms the outer skin 11 is defined as a first layer, and the layers laminated inward are defined as a second layer and a third layer in order.

  When the wind turbine blade is manufactured, the first-layer member is not formed with groove-shaped cuts 5, 6 such as wedges or trapezoids, as shown in FIG. This is because the fibers constituting the outer skin 11 fall into the cut lines 5 and 6, and the outer skin surface becomes uneven. When using a layer member with wedge-shaped or trapezoidal cuts 5 and 6 in the first layer, the upper and lower surfaces of the first layer are reversed or laminated, or the upper and lower surfaces of all layer members are reversed. And stack.

Next, a method for manufacturing the FRP structure 1 according to the present embodiment will be described.
First, a plate-shaped synthetic resin material 2 is prepared, and a plurality of cuts 3 are formed in the thickness direction from one surface side. The cut 3 is formed in a lattice shape, for example. On the other hand, a sheet material 4 that matches the area of the synthetic resin material 2 is prepared, and the sheet material 4 is attached to the synthetic resin material 2. The surface of the synthetic resin material 2 to which the sheet material 4 is attached is the surface opposite to the surface on which the cut 3 is formed. Thereby, the layer member which consists of the synthetic resin material 2 and the sheet material 4 is formed. The layer member can be handled as one member even if the synthetic resin material 2 is divided into a plurality of blocks by the cuts 3. Further, the layer member can be bent along the cut 3 and can be carried in and out in a wound form as shown in FIG.

  In the above description, the cut 3 is formed in the synthetic resin material 2 before the sheet material 4 is attached to the synthetic resin material 2, but the present invention is not limited to this example. Unless the sheet material 4 is cut, the cut line 3 may be formed in the synthetic resin material 2 after the sheet material 4 is attached to the synthetic resin material 2.

Next, the case where the FRP structure 1 in which the layer members are stacked is used as the core material of the wind turbine blade 10 will be described.
First, as shown in FIG. 4, the layer member formed as described above is placed on the reinforcing fiber 11 that forms the outer skin placed on the mold 20. Then, a plurality of layer members are stacked. Since the layer member has the cut 3, the layer member can be arranged to follow the curved surface of the mold 20. A structure in which a plurality of layer members are stacked is the FRP structure 1, and the FRP structure 1 is applied as a core material of the wind turbine blade 10.

  When manufacturing a wind turbine blade, in addition to the core material, a reinforcing fiber that forms a spar cap 12 between the FRP structures 1 as the core material as shown in FIG. Install on the reinforcing fiber that will form. Then, as shown in FIG. 4, reinforcing fibers that will form the outer skin 11 are also installed on the FRP structure 1 and the spar cap 12. Thereafter, these materials are sealed with a film bag by, for example, VaRTM method, and the base material resin is injected while evacuating the inside of the film bag, so that the outer skin 11, the cut 3 of the FRP structure 1, the through hole 7, etc. Infiltrate the base resin. Thereby, the wind turbine blade 10 made of FRP is manufactured. Here, an example in which the spar cap is formed at the same time as the blade has been described, but the spar cap may be separately formed in advance and integrated when the outer skin is formed.

  As described above, the FRP structure 1 according to the present embodiment can reduce the number of members in the planar direction, particularly in the longitudinal direction of the core material, by connecting the layer members with the single sheet material 4. Moreover, since the cut 3 is formed in the synthetic resin material 2 among the layer members, the FRP structure 1 can follow the curved surface. In addition, since the FRP structure 1 can be taken into and out of a manufacturing site such as a factory in a wound state and can be installed by expanding, the installation man-hour can be reduced and the installation at the installation location is easy. .

  Furthermore, when the FRP product (for example, FRP windmill blade 10) is manufactured without causing the respective members to move and shift independently by connecting the layer members with one sheet material 4, FRP It is difficult to cause wrinkles on the fiber that contacts the structure 1. Therefore, there is no risk of strength reduction due to wrinkles, and the quality of the FRP product can be improved.

  Moreover, according to the windmill blade 10 provided with said FRP structure 1, and the windmill provided with the windmill blade 10, it becomes possible to manufacture the windmill blade 10 and a windmill easily by providing the FRP structure 1. As compared with the case where a conventional core material made of a member having a limited number is used, a decrease in strength can be avoided.

DESCRIPTION OF SYMBOLS 1 FRP structure 2 Synthetic resin material 3, 5, 6 Cut 4 Sheet material 10, 30 Windmill blade 11, 31 Outer skin 12 Spar cap 20 Type 32 Balsa plywood material 33 Joint

Claims (6)

A plate-shaped synthetic resin material having a plurality of cuts formed in the thickness direction from one surface side;
A sheet material affixed to the other side of the synthetic resin material;
A layer member having
A reinforced plastic structure in which a plurality of the layer members are laminated.   2. The reinforced plastic structure according to claim 1, wherein the cut has a wider width on the one surface side of the synthetic resin material than on the other surface side. A step of forming a plurality of cuts in the thickness direction from one side to the plate-shaped synthetic resin material;
Affixing a sheet material on the other surface side of the synthetic resin material;
Laminating the synthetic resin material and the layer member having the sheet member;
For producing a reinforced plastic structure comprising: A plate-like core material having a plurality of cuts formed in the thickness direction from one surface side;
A sheet material affixed to the other surface of the core material;
A layer member having
A structure in which a plurality of layer members are stacked.   A reinforced plastic structure according to claim 1 or 2, or a windmill blade comprising the structure according to claim 4. A windmill comprising the windmill blade according to claim 5.

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