WO2023024003A1 - 一种用于风机叶片的增强芯材及其制备方法 - Google Patents

一种用于风机叶片的增强芯材及其制备方法 Download PDF

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Publication number
WO2023024003A1
WO2023024003A1 PCT/CN2021/114661 CN2021114661W WO2023024003A1 WO 2023024003 A1 WO2023024003 A1 WO 2023024003A1 CN 2021114661 W CN2021114661 W CN 2021114661W WO 2023024003 A1 WO2023024003 A1 WO 2023024003A1
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Prior art keywords
core material
reinforcement
reinforcements
fibers
reinforced core
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PCT/CN2021/114661
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English (en)
French (fr)
Inventor
张靖婧
张向阳
马豪
眭建军
徐刚
孙建旭
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远景能源有限公司
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Priority to CN202180002519.1A priority Critical patent/CN113853296B/zh
Priority to PCT/CN2021/114661 priority patent/WO2023024003A1/zh
Publication of WO2023024003A1 publication Critical patent/WO2023024003A1/zh

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Definitions

  • the invention relates to the technical field of wind power generation, in particular to a reinforced core material for fan blades and a preparation method thereof.
  • Fan blades are key components in wind turbines, and their key components include main girders, trailing edge girders, webs and shells.
  • the shell is a sandwich structure composed of core material and upper and lower skins, which accounts for the largest proportion of the fan blade area, and the core material in the sandwich structure is one of the key materials of the fan blade.
  • the sandwich materials used in batches on blades mainly include balsa wood and rigid closed-cell foam.
  • the specific strength and specific modulus of balsa wood are relatively high, but affected by various factors, the raw material supply and price of balsa wood are unstable. Therefore, at present, hard closed-cell foam is mostly used to make core materials.
  • Rigid foam is usually formed by foaming PET or PVC, and its strength and modulus are far from those of balsa wood.
  • the present invention provides a reinforced core material for fan blades, including:
  • the reinforcing body distributed inside the core material includes N first reinforcing bodies and M second reinforcing bodies distributed at intervals, wherein the tensile modulus and tensile strength of the first reinforcing body are greater than that of the first reinforcing body
  • Two reinforcements, any one of the first reinforcements is formed by K types of fibers of the same or different shapes infiltrated with resin, and the second reinforcement is a synthetic high polymer, wherein N, M, and K are natural numbers.
  • the fibers include glass fibers and/or carbon fibers and/or aramid fibers and/or natural fibers and/or ultra-high molecular weight polyethylene fibers and/or basalt fibers.
  • the fibers are in the form of fabric, chopped strand mat or laid cloth.
  • the resin includes thermosetting or thermoplastic resin.
  • the high polymer includes thermosetting or thermoplastic resin.
  • the material of the core material is a thermoplastic polymer or a thermosetting polymer or a material containing wood fibers or their copolymers and mixtures.
  • the profile of the first surface of the core material is linear, or wavy, or zigzag, or irregular, or a combination of any of the above shapes.
  • both the first reinforcement and the second reinforcement are arranged perpendicular to the first surface of the core material, and the height of the second reinforcement is less than or equal to the thickness of the core material.
  • the profile of the first reinforcing body and/or the second reinforcing body is rectangular, or triangular, or trapezoidal, or wavy, or zigzag, or grid-shaped, or a combination of any of the above-mentioned profiles.
  • any one of the first reinforcements and any one of the second reinforcements are the same or different.
  • Another aspect of the present invention provides the manufacturing method of the above-mentioned reinforced core material, comprising:
  • a second reinforcement is formed on the pre-reinforcement core.
  • the second reinforcing body is made by vacuum infusion, or resin transfer molding, extrusion, injection molding, or hand lay-up.
  • the present invention also provides a fan blade manufactured by using the above-mentioned reinforced core material, the fan blade includes a main beam, a web and a shell, and the main beam, web and shell include a sandwich structure and upper and lower The skin, wherein the sandwich structure is formed by stacking one or more reinforcing core materials as described above.
  • the material of the upper and lower skins is glass fiber or carbon fiber reinforced polymer.
  • first reinforcement and the second reinforcement in the sandwich structure are distributed at intervals.
  • the number of second reinforcing bodies between two adjacent first reinforcing bodies is any number.
  • the distances between two adjacent reinforcing bodies are equal or unequal.
  • first reinforcing body and the second reinforcing body in the sandwich structure are distributed at intervals.
  • the number of second reinforcing bodies between two adjacent first reinforcing bodies is any number.
  • the distances between two adjacent reinforcing bodies are equal or unequal.
  • the invention provides a reinforced core material for fan blades.
  • the first and second reinforcements into the core material, while improving the specific strength and specific modulus of the core material, it maintains a relatively low Infusion density, less changes to the molding and processing technology of the existing core material, strong achievability, less investment in additional equipment, and thus a high overall cost performance.
  • the introduction of the second reinforcing body can also make the whole reinforcing core material flexible.
  • the grammage and type of fibers in the first reinforcement can be adjusted as needed, or the types of resins in the first reinforcement and the second reinforcement can be adjusted, thereby adjusting the mechanical properties of the reinforced core material.
  • the inventors have found through research that a sandwich structure formed by alternately distributing materials with high strength and modulus parameters and materials with low strength and modulus parameters in the core material can be used in While making the specific strength and specific modulus of the core material higher, the sandwich sandwich structure has higher flexibility, thereby improving the safety margin of the blade structure design; the applicant found through research that, especially, the strength and the modulus parameter is selected as tensile strength and tensile modulus, that is, when the material with a large difference in the two parameters of tensile strength and tensile modulus is selected as the material of the first and second reinforcements, it can maximize The specific strength and specific modulus of the material, while taking into account the overall toughness of the sandwich sandwich structure.
  • Fig. 1 shows a schematic structural view of a reinforced core material for a fan blade according to an embodiment of the present invention
  • Figures 2a-2c respectively show structural schematic diagrams of reinforced core materials with multiple different contour surfaces in the embodiment of the present invention
  • Figures 3a-3e respectively show the structural schematic diagrams of multiple reinforcing bodies with different shapes in the embodiment of the present invention.
  • Figures 4a-4c respectively show the structural schematic diagrams of multiple reinforcing bodies with different distribution angles in the embodiment of the present invention
  • Fig. 5 shows a schematic flow diagram of a method for preparing a reinforced core material for fan blades according to an embodiment of the present invention
  • Figure 6 shows a schematic structural view of a fan blade according to an embodiment of the present invention.
  • Fig. 1 shows a schematic structural view of a reinforced core material for a fan blade according to an embodiment of the present invention.
  • a reinforced core material for a fan blade includes a core material 101 , a first reinforcement 102 and a second reinforcement 103 .
  • the first reinforcing body 102 and the second reinforcing body 103 are distributed in the core material 101 at intervals, wherein the tensile modulus and tensile strength of the first reinforcing body 102 are significantly greater than that of the second reinforcing body 103 .
  • the term "A is significantly greater than B" means that A is at least 150%, especially more than 200%, such as 300%, 400%, 500%, 1000%, etc. of B.
  • the first reinforcing body 102 and the second reinforcing body 103 extend transversely to the length direction of the reinforcing core material 101 .
  • the term "A is transverse to B" means that A and B form an angle greater than 0, such as being inclined to, perpendicular to.
  • there may be x number of second reinforcements 103 distributed between any two adjacent first reinforcements 102 or there may be y number of reinforcements 103 distributed between any adjacent two second reinforcements 103
  • the first reinforcement 102 wherein both x and y are integers greater than or equal to 0.
  • the distance between any two adjacent reinforcements can be the same or different, wherein the two adjacent reinforcements can be two first reinforcements, or one first reinforcement body and a second reinforcement, or two second reinforcements.
  • the material of the core material 101 may include thermoplastic polymers, thermosetting polymers, materials containing wood fibers, and their copolymers, mixtures and modified products.
  • the thermoplastic polymer includes polyester, polyvinyl chloride, polyamide, polystyrene, polyacrylate, polyacrylic acid, polyolefin, polycycloolefin, polyacrylonitrile, polyether amide, polyether ester, polycarbonate Esters, polyethers, polysulfones, polyketones, polyimides, polyphenylene esters, and their copolymers, mixtures and modified products;
  • the thermosetting polymers include epoxy resins, polyurethanes, phenolic, unsaturated polyesters , vinyl, silicone, modified silane, cycloolefin, acrylic acid, bismaleimide, allyl resin, furan resin, amino resin, alkyd resin, and their copolymers, mixtures and modified products, etc.
  • the material containing wood fiber may include naturally grown balsa wood, pa
  • the first reinforcement and the second reinforcement extend from the first surface 001 of the core material to the inside, but do not exceed the second surface 002 of the core material.
  • any The lengths of a first reinforcement and/or a second reinforcement may be the same or different, wherein the first surface and the second surface of the core material refer to two surfaces perpendicular to the thickness direction of the core material.
  • the profile of the first surface of the core material can be in various shapes, and Figs. 2a-2c respectively show structural schematic diagrams of reinforcing core materials with multiple different profile surfaces in the embodiment of the present invention.
  • the profile of the first surface of the core material can be straight (Figure 1), wavy (Figure 2a), zigzag (Figure 2b) , irregular shape (Figure 2c), or a combination of any of the above shapes.
  • contours of the first reinforcement and the second reinforcement there is no restriction on the contours of the first reinforcement and the second reinforcement, and the contours of any first reinforcement and/or second reinforcement contained in the same reinforcement core material are the same. They can be the same or different, that is, in the same reinforced core material, multiple first reinforcements and second reinforcements with different or identical shapes and profiles can be included.
  • Figures 3a-3e respectively show the schematic structural views of a plurality of reinforcements with different shapes in the embodiment of the present invention, as shown in Figures 1 and 3a-3e, the outline of the first reinforcement and/or the second reinforcement can be It is rectangular (Figure 1), triangular (Figure 3a), trapezoidal (Figure 3b), wavy (Figure 3c), zigzag (Figure 3d), mesh ( Figure 3e) or a combination of any of the above profiles.
  • the first reinforcing body and the second reinforcing body can be arranged parallel to the thickness direction of the core material, that is, perpendicular to the first surface of the core material, or can be arranged with the core material There is a certain included angle in the thickness direction, and in the same reinforced core material, the arrangement direction of any first reinforcement and/or second reinforcement can be the same or different.
  • 1 and 4a-4c respectively show the structural schematic diagrams of multiple reinforcing bodies with different distribution angles in the embodiment of the present invention. In the embodiment shown in Figure 1, both the first reinforcement and the second reinforcement are perpendicular to the first surface of the core material, and the height of the second reinforcement is less than or equal to the height of the core material. thickness.
  • any one of the first reinforcements 102 is a fiber-reinforced resin composite material, which is formed by infiltrating one or more fibers of the same or different shapes with resin.
  • the fibers include glass fibers, carbon fibers, aramid fibers, natural fibers, ultra-high molecular weight polyethylene fibers or basalt fibers, etc., which can be in the form of fabrics, chopped strand mats or laid cloths , wherein, if a fabric is used, the fabric can be a non-curling fabric or a curling fabric, and the non-curling fabric includes unidirectional, biaxial and triaxial fabrics, etc., and the curling fabric can be plain weave, twill weave, satin weave and the like.
  • the fiber impregnated with resin is in the form of prepreg, unsaturated polyester glass fiber reinforced molding compound SMC, bulk molding compound BMC or the like.
  • the resin used may be a synthetic polymer compound, for example, may include thermosetting and thermoplastic resins.
  • thermosetting resin includes epoxy, polyurethane, unsaturated polyester, phenolic, vinyl, silicone, modified silane, cycloolefin, acrylic acid, bismaleimide, allyl, furan, amino, alcohol acid resin, etc.
  • thermoplastic resin includes polyolefin, polycycloolefin, polyvinyl chloride, polystyrene, polyacrylic acid, polyacrylate, polyamide, polyacrylonitrile, polyether amide, polyether ester, polycarbonate , polyoxymethylene, thermoplastic polyester, polyether, fluororesin, polyphenylene sulfide, polyimide, polysulfone, polyketone, polyphenylene resin, etc., and one of its modified resins or polymer alloys, etc. .
  • the second reinforcing body 103 is a synthetic polymer compound, such as a thermosetting resin or a thermoplastic resin.
  • the thermosetting resin includes epoxy, polyurethane, unsaturated polyester, phenolic, vinyl, silicone, modified silane, cycloolefin, acrylic acid, bismaleimide, allyl, furan, amino, alcohol acid resin, etc.; and said thermoplastic resin includes polyolefin, polycycloolefin, polyvinyl chloride, polystyrene, polyacrylic acid, polyacrylate, polyamide, polyacrylonitrile, polyether amide, polyether ester, polycarbonate , polyoxymethylene, thermoplastic polyester, polyether, fluororesin, polyphenylene sulfide, polyimide, polysulfone, polyketone, polyphenylene resin, etc., and one of its modified resins or polymer alloys, etc.
  • the second reinforcing body 103 can
  • Fig. 5 shows a schematic flowchart of a method for preparing a reinforced core material for a fan blade according to an embodiment of the present invention.
  • a method for preparing a reinforced core material for fan blades comprising:
  • a first reinforcement is made.
  • Fibers are impregnated with resin to obtain the first reinforcement, wherein the fibers include glass fibers, carbon fibers, aramid fibers, natural fibers, ultra-high molecular weight polyethylene fibers or basalt fibers, etc., and fabrics, chopped strand mats or laid-off fibers can be used
  • the form of cloth, if fabric is used, the fabric can be non-curling fabric or curly fabric, non-curling fabric includes unidirectional, biaxial and triaxial fabric, etc., and curly fabric can be in the form of plain weave, twill weave, satin weave, etc.
  • the resin can be epoxy, polyurethane, unsaturated polyester, phenolic, vinyl, silicone, modified silane, cycloolefin, acrylic, bismaleimide, allyl, furan, amino, alcohol
  • Thermosetting resins such as acid resins, polyolefins, polycycloolefins, polyvinyl chloride, polystyrene, polyacrylic acid, polyacrylate, polyamide, polyacrylonitrile, polyetheramide, polyetherester, polycarbonate, polyoxymethylene , thermoplastic polyester, polyether, fluororesin, polyphenylene sulfide, polyimide, polysulfone, polyketone, polyphenylene resin and other thermoplastic resins, or one of its modified resins or polymer alloys, etc., or other polymer compounds;
  • the first reinforcement and the core material are cured.
  • the first reinforcing body and the core material are cured by means of pressure curing or heat curing to obtain a pre-reinforced core material, wherein the pressure curing includes methods such as vacuum bag pressurization, mechanical tooling pressurization, etc., and the The heating and curing include contact and non-contact heating methods, such as oven heating, microwave heating, far-infrared heating, welding, etc.; and
  • a second reinforcement is formed.
  • a second reinforcement is formed on the pre-reinforcement core, and the second reinforcement is made, for example, by vacuum infusion, or resin transfer molding, extrusion, injection molding, or hand lay-up.
  • the making of the second reinforcement includes:
  • thermosetting resin includes epoxy, polyurethane, unsaturated polyester, vinyl, phenolic, silicone, modified silane, cycloolefin, acrylic acid, bismaleimide, allyl, furan, amino, alcohol acid resin, etc.
  • thermoplastic resin includes polyolefin, polycycloolefin, polyvinyl chloride, polystyrene, polyacrylic acid, polyacrylate, polyamide, polyacrylonitrile, polyether amide, polyether ester, polycarbonate , polyoxymethylene, thermoplastic polyester, polyether, fluororesin, polyphenylene sulfide, polyimide, polysulfone, polyketone, polyphenylene resin, etc., and one of its modified resins or polymer alloys, etc. .
  • Fig. 6 shows a schematic structural view of a fan blade according to an embodiment of the present invention.
  • a fan blade includes a leading edge 601, main beams 621 and 622, a pressure surface 603, a suction surface 604 and a trailing edge 605, and at the same time, two webs are fixed between the two main beams 621 and 622.
  • Plates 661 and 662, wherein the main girder, web, pressure face, suction face and tail boom include upper and lower skins and a sandwich structure.
  • the material of the upper and lower skins can be glass fiber or carbon fiber reinforced polymer, and the reinforced core material as mentioned above can be applied in the sandwich structure, that is, the sandwich structure can be composed of one or A plurality of reinforcing core materials as described above are stacked.
  • the distribution of the first reinforcing body and the second reinforcing body included in the sandwich structure of different fan blades or different parts may be the same or different.
  • the direction parallel to the length of the blade is taken as the first direction
  • the direction parallel to the chord direction of the blade is taken as the second direction
  • the direction parallel to the thickness of the blade is taken as the third direction.
  • the first reinforcing body and the second reinforcing body may be distributed at intervals, wherein every two individual first reinforcing bodies There can be one or more second reinforcements between them, or there can be one or more first reinforcements between every two separate second reinforcements, and at the same time, the distance between any two adjacent reinforcements can be Equal or unequal, wherein, any two adjacent reinforcements can be two first reinforcements, or one first reinforcement and one second reinforcement, or two second reinforcements.
  • first reinforcing body and the second reinforcing body may also be distributed at intervals, wherein there may be one or more reinforcing bodies between every two individual first reinforcing bodies second reinforcing body, or there may be one or more first reinforcing bodies between every two individual second reinforcing bodies, and at the same time, the distance between any two adjacent reinforcing bodies may be equal or unequal, wherein , any two adjacent reinforcements may be two first reinforcements, or one first reinforcement and one second reinforcement, or two second reinforcements.
  • first reinforcement or the second reinforcement in the direction parallel to the first direction, only the first reinforcement or the second reinforcement may be arranged, and any two adjacent first reinforcements or second reinforcements The distance between reinforcements may be equal or unequal.
  • 7a-7c respectively show the structural schematic diagrams of the sandwich structure of a plurality of different fan blades in the embodiment of the present invention.
  • the first reinforcing body and the second reinforcing body are arranged at intervals, as shown in Figure 7b
  • the first reinforcement body and the second reinforcement body are arranged at intervals, but in the direction parallel to the first direction, only the first reinforcement body is arranged body
  • the first reinforcement body and the second reinforcement body are arranged at intervals, but in the direction parallel to the first direction, Only the second reinforcement is arranged.
  • the number of second reinforcing bodies between two adjacent first reinforcing bodies is not limited to that shown in the figure One, but can be multiple, and the number of second reinforcements between any adjacent two first reinforcements can be different, and for example, the number of first reinforcements between adjacent two second reinforcements
  • the number is not limited to one as shown in the figure, but can be multiple, and the number of first reinforcements between any two adjacent second reinforcements can be different.
  • the invention provides a reinforced core material for fan blades.
  • the specific strength and specific modulus of the core material are improved while maintaining its relatively low Infusion density, less changes to the molding and processing technology of the existing core material, strong achievability, less investment in additional equipment, and thus a high overall cost performance.
  • the introduction of the second reinforcing body can also make the whole reinforcing core material flexible.
  • the grammage and type of fibers in the first reinforcement can be adjusted as needed, or the types of resins in the first reinforcement and the second reinforcement can be adjusted, thereby adjusting the mechanical properties of the reinforced core material.

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Abstract

本发明提供一种用于风机叶片的增强芯材，包括芯材以及分布于芯材内部的增强体，增强体包括彼此间隔开且交替分布的一个或多个第一增强体及一个或多个第二增强体，其中，第一增强体和第二增强体横向于增强芯材的长度方向延伸并且第一增强体的拉伸模量及拉伸强度分别大于第二增强体的拉伸模量及拉伸强度，且第一增强体由一种或多种相同或不同形态的纤维经树脂浸润后形成，以及第二增强体为合成的高聚物。

Description

一种用于风机叶片的增强芯材及其制备方法 技术领域
本发明涉及风力发电技术领域，特别涉及一种用于风机叶片的增强芯材及其制备方法。
背景技术
风机叶片是风力发电机中的关键部件，其关键部件有主梁、尾缘梁、腹板和壳体。其中，壳体是由芯材和上下蒙皮组成的夹心结构，其占风机叶片面积的比例最大，而夹心结构中的芯材是风机叶片的关键材料之一。
目前，叶片上批量使用的夹芯材料主要包括轻木和硬质闭孔泡沫。其中，轻木的比强度和比模量比较高，但是受到各种因素的影响，轻木的原材料供货和价格不稳定，因此，目前多采用硬质闭孔泡沫制作芯材。硬质泡沫通常由PET或PVC通过发泡成型，其材料的强度和模量均与轻木有较大的差距。
通过提高泡沫的密度可以提高其的力学性能，但树脂吸收量，叶片重量和材料的成本也大幅增加。
发明内容
针对现有技术中的部分或全部问题，本发明一方面提供一种用于风机叶片的增强芯材，包括：
芯材；以及
分布于所述芯材内部的增强体，包括间隔分布的N个第一增强体及M个第二增强体，其中，所述第一增强体的拉伸模量及拉伸强度大于所述第二增强体，任一所述第一增强体由K种相同或不同形态的纤维经树脂浸润后形成，以及所述第二增强体为合成的高聚物，其中N、M、K为自然数。
进一步地，所述纤维包括玻璃纤维和/或碳纤维和/或芳纶纤维和/或天然纤维和/或超高分子量聚乙烯纤维和/或玄武岩纤维。
进一步地，所述纤维为织物、短切毡或无纬布的形式。
进一步地，所述树脂包括热固性或热塑性树脂。
进一步地，所述高聚物包括热固性或热塑性树脂。
进一步地，所述芯材的材料为热塑性聚合物或热固性聚合物或含有木纤维的材料或它们的共聚物和混合物。
进一步地，所述芯材的第一表面的轮廓为直线形、或波浪形、或锯齿形、或不规则形、或上述任意形状的组合。
进一步地，任一所述第一增强体和/或第二增强体与所述芯材的第一表面存在夹角。
进一步地，所述第一增强体及第二增强体均垂直于所述芯材的第一表面布置，且所述第二增强体的高度小于或等于所述芯材的厚度。
进一步地，所述第一增强体和/或第二增强体的轮廓为矩形、或三角形、或梯形、或波浪形、或锯齿形、或网格形、或上述任意轮廓的组合。
进一步地，任一所述第一增强体及任一所述第二增强体的尺寸和/或形状相同或不同。
本发明另一方面提供如上所述的增强芯材的制造方法，包括：
采用树脂浸润纤维，得到第一增强体；
通过加压固化或加热固化的方式，将第一增强体与芯材固化，得到预增强芯材；以及
在所述预增强芯材上形成第二增强体。
进一步地，所述第二增强体通过真空灌注、或树脂传递模塑、挤出、注塑、手糊方式制成。
本发明还提供一种采用如上所述的增强芯材制作得到的风机叶片，所述风机叶片包括主梁、腹板和壳体，所述主梁、腹板和壳体包括夹芯结构和上下蒙皮，其中，所述夹芯结构由一块或多块如上所述的增强芯材堆叠形成。
进一步地，所述上下蒙皮的材料为玻璃纤维或碳纤维增强的聚合物。
进一步地，在平行于叶片弦向的方向上，所述夹心结构中的第一增强体与第二增强体呈间隔分布。
进一步地，相邻两个第一增强体之间的第二增强体数量为任意数。
进一步地，相邻两个增强体之间的距离相等或不等。
进一步地，在平行于叶片长度的方向上，所述夹心结构中的第一增强体与第二增强体呈间隔分布。
进一步地，相邻两个第一增强体之间的第二增强体数量为任意数。
进一步地，相邻两个增强体之间的距离相等或不等。
本发明提供的一种用于风机叶片的增强芯材，通过在芯材中引入第一及第二增强体，在提升芯材的比强度及比模量的同时，保持了其相对较低的灌注密度，且对现有芯材的成型和加工工艺的改动较少，可实现性强，所需的额外设备投资少，从而具有较高的综合性价比。此外，第二增强体的引入还可使得增强芯材整体具有柔性。在实际应用中，可以根据需要调整第一增强体中纤维的克重和类型，或调整第一增强体和第二增强体中树脂的类型，进而调整增强芯材的力学性能。这基于发明人的如下洞察，发明人通过研究发现，通过在芯材中交替分布具有高强度和模量参数的材料和具有低强度和模量参数的材料所形成的三明治夹芯结构，可以在使芯材的比强度和比模量较高的同时，还使三明治夹芯结构具有较高的柔韧性，从而提高叶片结构设计的安全余量；申请人通过研究发现，尤其是将所述强度和模量参数选择为拉伸强度和拉伸模量、即选择拉伸强度和拉伸模量这两个参数具有较大差异的材料为第一和第二增强体的材料时，能够最大化材料的比强度、比模量、同时兼顾三明治夹芯结构整体的韧性。
附图说明
为进一步阐明本发明的各实施例的以上和其它优点和特征，将参考附图来呈现本发明的各实施例的更具体的描述。可以理解，这些附图只描绘本发明的典型实施例，因此将不被认为是对其范围的限制。在附图中，为了清楚明了，相同或相应的部件将用相同或类似的标记表示。
图1示出本发明一个实施例的一种用于风机叶片的增强芯材的结构示意图；
图2a-2c分别示出本发明实施例中多个不同轮廓表面的增强芯材的结构示意图；
图3a-3e分别示出本发明实施例中多个不同形状增强体的结构示意图；
图4a-4c分别示出本发明实施例中多个不同分布角度的增强体的结构示意图；
图5示出本发明一个实施例的一种用于风机叶片的增强芯材的制备方法的流程示意图；
图6示出本发明一个实施例的一种风机叶片的结构示意图；以及
图7a-7c分别示出本发明实施例中多个不同风机叶片的夹心结构的结构示意图。
具体实施方式
以下的描述中，参考各实施例对本发明进行描述。然而，本领域的技术人员将认识到可在没有一个或多个特定细节的情况下或者与其它替换和/或附加方法、材料或组件一起实施各实施例。在其它情形中，未示出或未详细描述公知的结构、材料或操作以免模糊本发明的发明点。类似地，为了解释的目的，阐述了特定数量、材料和配置，以便提供对本发明的实施例的全面理解。然而，本发明并不限于这些特定细节。此外，应理解附图中示出的各实施例是说明性表示且不一定按正确比例绘制。
在本说明书中，对“一个实施例”或“该实施例”的引用意味着结合该实施例描述的特定特征、结构或特性被包括在本发明的至少一个实施例中。在本说明书各处中出现的短语“在一个实施例中”并不一定全部指代同一实施例。
需要说明的是，本发明的实施例以特定顺序对工艺步骤进行描述，然而这只是为了阐述该具体实施例，而不是限定各步骤的先后顺序。相反，在本发明的不同实施例中，可根据工艺的调节来调整各步骤的先后顺序。
为了提供一种原材料供应稳定、成本可控、且力学性能满足需求的夹芯材料，以制造风机叶片。本发明对现有的芯材及其制备方法进行改进，提供了一种用于风机叶片的增强芯材及其制备方法。下面结合实施例附图，对本发明的方案作进一步描述。
图1示出本发明一个实施例的一种用于风机叶片的增强芯材的结构示意图。如图1所示，一种用于风机叶片的增强芯材，包括芯材101、第一增强体102以及第二增强体103。所述第一增强体102以及第二增 强体103间隔分布于所述芯材101内部，其中，所述第一增强体102的拉伸模量及拉伸强度显著大于所述第二增强体103。在本申请中，术语“A显著大于B”是指A为B的至少150％、尤其是200％以上、例如300％、400％、500％、1000％等等。所述第一增强体102和第二增强体103横向于增强芯材101的长度方向延伸。在本发明中，术语“A横向于B”是指A与B成大于0的角度、例如倾斜于、垂直于。在本发明的一个实施例中，任意相邻两个第一增强体102之间可能分布有x个第二增强体103，或任意相邻两个第二增强体103之间可能分布有y个第一增强体102，其中，x、y均为大于等于0的整数。在本发明的又一个实施例中，任意相邻的两个增强体之间的距离可以相同或不同，其中，相邻的两个增强体可以为两个第一增强体，或一个第一增强体与一个第二增强体，或两个第二增强体。
所述芯材101的材料可以包括热塑性聚合物、热固性聚合物、含有木纤维的材料、以及它们的共聚物、混合物和改性物。其中，所述热塑性聚合物包括聚酯、聚氯乙烯、聚酰胺、聚苯乙烯、聚丙烯酸酯、聚丙烯酸、聚烯烃、聚环烯烃、聚丙烯腈、聚醚酰胺、聚醚酯、聚碳酸酯、聚醚、聚砜、聚酮、聚酰亚胺、聚苯酯、以及他们的共聚物、混合物和改性物；所述热固性聚合物包括环氧树脂、聚氨酯、酚醛、不饱和聚酯、乙烯基、有机硅、改性硅烷、环烯烃、丙烯酸、双马来酰亚胺、烯丙基树脂、呋喃树脂、氨基树脂、醇酸树脂，以及它们的共聚物、混合物和改性物等；以及所述含有木纤维的材料可以包括天然生长的轻木、泡桐木、杨木、柳木、榆木、槐木、以及由其中两种或两种以上木纤维材料结合而成的复合体等。
所述第一增强体及第二增强体自所述芯材的第一表面001向其内部延升，但不超出所述芯材的第二表面002，同一增强芯材中，所包含的任一第一增强体和/或第二增强体的长度可以相同或不同，其中，所述芯材的第一表面及第二表面指与所述芯材厚度方向垂直的两个表面。在本发明的实施例中，所述芯材的第一表面的轮廓可以为多种形状，图2a-2c分别示出本发明实施例中多个不同轮廓表面的增强芯材的结构示意图。如图1及2a-2c所示，在本发明的实施例中，所述芯材的第一表面的轮廓可以是直线形(图1)、波浪形(图2a)、锯齿形(图2b)、不规则形(图2c)、或上述任意形状的组合。
在本发明的实施例中，所述第一增强体及第二增强体的轮廓没有限制，且同一增强芯材中，所包含的任一第一增强体和/或第二增强体的轮廓均可以相同或不同，即在同一增强芯材中，可以包含多个不同或相同形状轮廓的第一增强体及第二增强体。图3a-3e分别示出本发明实施例中多个不同形状增强体的结构示意图，如图1及3a-3e所示，所述第一增强体和/或所述第二增强体的轮廓可以是矩形(图1)、三角形(图3a)、梯形(图3b)、波浪形(图3c)、锯齿形(图3d)、网格形(图3e)或上述任意轮廓的组合。
在本发明的实施例中，所述第一增强体及第二增强体可以平行于所述芯材的厚度方向布置，即垂直于所述芯材的第一表面，也可以与所述芯材的厚度方向存在一定的夹角，且同一增强芯材中，任一第一增强体和/或第二增强体的布置方向可以相同或不同。图1及4a-4c分别示出本发明实施例中多个不同分布角度的增强体的结构示意图。如图1所示的实施例中，所述第一增强体及第二增强体均垂直于所述芯材的第一表面，且所述第二增强体的高度小于或等于所述芯材的厚度。如图4a所示的实施例中，所述第一增强体与所述芯材的第一表面之间存在夹角α，且所述夹角α满足0°≤α≤90°，相邻两个第一增强体之间包括垂直于所述芯材第一表面布置的第二增强体，相邻两个第一增强体优选呈镜像布置，在本发明其他实施例中，相邻两个第一增强体与其中间设置的第二增强体之间的夹角可以相同或不同。如图4b所示的实施例中，所述第二增强体与所述芯材的第一表面之间存在夹角β，且所述夹角β满足0°≤β≤90°，相邻两个第二增强体之间包括垂直于所述芯材第一表面布置的第一增强体，相邻两个第二增强体优选相对于所述第一增强体对称布置，在本发明其他实施例中，相邻两个第二增强体与其中间设置的第一增强体之间的夹角可以相同或不同。如图4c所示的实施例中，所述第一增强体及第二增强体与所述芯材的第一表面之间均存在夹角，进而使得相邻的第一增强体及第二增强体之间形成有夹角γ，且所述夹角γ满足0°≤γ≤90°。应当理解的是，所述第一增强体和/或第二增强体的布置方向并不限于如图所示的情况，且同一增强芯材中，任一第一增强体和/或第二增强体的布置方向可以相同或不同。
在本发明的一个实施例中，任一所述第一增强体102为纤维增强树脂复合材料，其由一种或多种相同或不同形态的纤维经树脂浸润后形 成。在本发明的一个实施例中，所述纤维包括玻璃纤维、碳纤维、芳纶纤维、天然纤维、超高分子量聚乙烯纤维或玄武岩纤维等，其可采用织物、短切毡或无纬布的形式，其中，若采用织物，则所述织物可以为非卷曲面料或卷曲面料，非卷曲面料包括单向、双轴和三轴面料等，以及卷曲面料则可以为平纹、斜纹、缎纹等形式。上述不同形式的纤维在单独的一层第一增强体中可以单独存在，也可以复合的形式存在。在本发明的一个实施例中，所述浸润有树脂的纤维的为预浸料、不饱和聚酯玻璃纤维增强模塑料SMC、团状模塑料BMC等形式。其中，使用的树脂可以是合成的高分子化合物，例如可包括热固性和热塑性树脂。其中，所述热固性树脂包括环氧、聚氨酯、不饱和聚酯、酚醛、乙烯基、有机硅、改性硅烷、环烯烃、丙烯酸、双马来酰亚胺、烯丙基、呋喃、氨基、醇酸树脂等，以及所述热塑性树脂包括聚烯烃、聚环烯烃、聚氯乙烯、聚苯乙烯、聚丙烯酸、聚丙烯酸酯、聚酰胺、聚丙烯腈、聚醚酰胺、聚醚酯、聚碳酸酯、聚甲醛、热塑性聚酯、聚醚、氟树脂、聚苯硫醚、聚酰亚胺、聚砜、聚酮、聚苯酯树脂等，及其改性树脂或聚合物合金等中的一种。
在本发明的一个实施例中，所述第二增强体103为合成的高分子化合物，例如可以为热固性树脂或热塑性树脂。其中，所述热固性树脂包括环氧、聚氨酯、不饱和聚酯、酚醛、乙烯基、有机硅、改性硅烷、环烯烃、丙烯酸、双马来酰亚胺、烯丙基、呋喃、氨基、醇酸树脂等；以及所述热塑性树脂包括聚烯烃、聚环烯烃、聚氯乙烯、聚苯乙烯、聚丙烯酸、聚丙烯酸酯、聚酰胺、聚丙烯腈、聚醚酰胺、聚醚酯、聚碳酸酯、聚甲醛、热塑性聚酯、聚醚、氟树脂、聚苯硫醚、聚酰亚胺、聚砜、聚酮、聚苯酯树脂等，及其改性树脂或聚合物合金等中的一种。在本发明的一个实施例中，所述第二增强体103可通过真空灌注、树脂传递模塑、挤出、注塑、手糊等方式成型。
图5示出本发明一个实施例的一种用于风机叶片的增强芯材的制备方法的流程示意图。如图5所示，一种用于风机叶片的增强芯材的制备方法，包括：
首先，在步骤501，制作第一增强体。采用树脂浸润纤维，得到第一增强体，其中，所述纤维包括玻璃纤维、碳纤维、芳纶纤维、天然纤维、超高分子量聚乙烯纤维或玄武岩纤维等，可采用织物、短切毡或无 纬布的形式，若采用织物，则所述织物可以为非卷曲面料或卷曲面料，非卷曲面料包括单向、双轴和三轴面料等，以及卷曲面料则可以为平纹、斜纹、缎纹等形式，以及所述树脂可以为环氧、聚氨酯、不饱和聚酯、酚醛、乙烯基、有机硅、改性硅烷、环烯烃、丙烯酸、双马来酰亚胺、烯丙基、呋喃、氨基、醇酸树脂等热固性树脂，以及聚烯烃、聚环烯烃、聚氯乙烯、聚苯乙烯、聚丙烯酸、聚丙烯酸酯、聚酰胺、聚丙烯腈、聚醚酰胺、聚醚酯、聚碳酸酯、聚甲醛、热塑性聚酯、聚醚、氟树脂、聚苯硫醚、聚酰亚胺、聚砜、聚酮、聚苯酯树脂等热塑性树脂，或其改性树脂或聚合物合金等中的一种，或其他高分子化合物；
接下来，在步骤502，固化第一增强体与芯材。通过例如加压固化或加热固化的方式，将第一增强体与芯材固化，得到预增强芯材，其中，所述加压固化包括例如真空袋加压、机械工装加压等方式，以及所述加热固化包括接触式和非接触式加热等方式，例如热烘箱加热、微波加热、远红外加热、焊接等；以及
最后，在步骤503，形成第二增强体。在所述预增强芯材上形成第二增强体，所述第二增强体例如通过真空灌注、或树脂传递模塑、挤出、注塑、手糊方式制成，在本发明的一个实施例中，所述第二增强体的制作包括：
在所述预增强芯材的预设位置进行打孔和/或开槽，得到深孔和/或深槽和/或浅槽；
在所述深孔和/或深槽和/或浅槽内填充高分子化合物，其中，所述高分子化合物例如可以为热固性树脂或热塑性树脂。其中，所述热固性树脂包括环氧、聚氨酯、不饱和聚酯、乙烯基、酚醛、有机硅、改性硅烷、环烯烃、丙烯酸、双马来酰亚胺、烯丙基、呋喃、氨基、醇酸树脂等；以及所述热塑性树脂包括聚烯烃、聚环烯烃、聚氯乙烯、聚苯乙烯、聚丙烯酸、聚丙烯酸酯、聚酰胺、聚丙烯腈、聚醚酰胺、聚醚酯、聚碳酸酯、聚甲醛、热塑性聚酯、聚醚、氟树脂、聚苯硫醚、聚酰亚胺、聚砜、聚酮、聚苯酯树脂等，及其改性树脂或聚合物合金等中的一种。
上述增强芯材及其制备方法可应用于风机叶片中。图6示出本发明一个实施例的一种风机叶片的结构示意图。如图6所示，一种风机叶片包括前缘601、主梁621和622、压力面603、吸力面604以及尾缘605， 同时，在两个主梁621和622之间固定有两块腹板661和662，其中，所述主梁、腹板、压力面、吸力面以及尾梁包括上下蒙皮以及夹芯结构。其中，所述上下蒙皮的材料可以为玻璃纤维或碳纤维增强的聚合物，而如前所述的增强芯材则可应用于所述夹芯结构中，即所述夹芯结构可以由一个或多个如前所述的增强芯材堆叠形成。
不同风机叶片或不同部位的夹芯结构中所包含的第一增强体及第二增强体的分布可以相同或不同。在本发明中，将平行于叶片长度的方向作为第一方向，平行于叶片弦向的方向作为第二方向，以及平行于叶片厚度的方向作为第三方向。则在风机叶片的夹芯结构中，在与所述第二方向平行的方向上，所述第一增强体与第二增强体可以呈间隔分布，其中，每两个单独的第一增强体之间可以有一个或多个第二增强体，或者每两个单独的第二增强体之间可以有一个或多个第一增强体，同时，任意相邻的两个增强体之间的距离可以相等或不相等，其中，任意相邻的两个增强体可以为两个第一增强体，或一个第一增强体与一个第二增强体，或两个第二增强体。类似的，在与所述第一方向平行的方向上，所述第一增强体与第二增强体也可以呈间隔分布，其中，每两个单独的第一增强体之间可以有一个或多个第二增强体，或者每两个单独的第二增强体之间可以有一个或多个第一增强体，同时，任意相邻的两个增强体之间的距离可以相等或不相等，其中，任意相邻的两个增强体可以为两个第一增强体，或一个第一增强体与一个第二增强体，或两个第二增强体。此外，在本发明的其他实施例中，在与所述第一方向平行的方向上，可以仅布置第一增强体或第二增强体，且任意相邻的两个第一增强体或第二增强体之间的距离可以相等或不相等。图7a-7c分别示出本发明实施例中多个不同风机叶片的夹心结构的结构示意图。其中，如图7a所示的结构中，在与所述第一方向平行的方向以及与所述第二方向平行的方向上，第一增强体与第二增强体均为间隔布置，图7b所示的结构中，在与所述第二方向平行的方向上，第一增强体与第二增强体均为间隔布置，但在与所述第一方向平行的方向上，仅布置有第一增强体，以及图7c所示的结构中，在与所述第二方向平行的方向上，第一增强体与第二增强体均为间隔布置，但在与所述第一方向平行的方向上，仅布置有第二增强体。应当理解的是，在本发明的其他实施例中，并不限于如图所示的布置方式，例如，相邻两个第一增强体之间的第二增强体的 数量不限于如图所示的一个，而可以为多个，且任意相邻两个第一增强体之间的第二增强体的数量可以不同，又例如，相邻两个第二增强体之间的第一增强体的数量也不限于如图所示的一个，而可以为多个，且任意相邻两个第二增强体之间的第一增强体的数量可以不同等。
本发明提供的一种用于风机叶片的增强芯材，通过在芯材中引入第一及第二增强体，提升了芯材的比强度及比模量的同时，保持了其相对较低的灌注密度，且对现有芯材的成型和加工工艺的改动较少，可实现性强，所需的额外设备投资少，从而具有较高的综合性价比。此外，第二增强体的引入还可使得增强芯材整体具有柔性。在实际应用中，可以根据需要调整第一增强体中纤维的克重和类型，或调整第一增强体和第二增强体中树脂的类型，进而调整增强芯材的力学性能。
尽管上文描述了本发明的各实施例，但是，应该理解，它们只是作为示例来呈现的，而不作为限制。对于相关领域的技术人员显而易见的是，可以对其做出各种组合、变型和改变而不背离本发明的精神和范围。因此，此处所公开的本发明的宽度和范围不应被上述所公开的示例性实施例所限制，而应当仅根据所附权利要求书及其等同替换来定义。

Claims (22)

  1. 一种用于风机叶片的增强芯材，其特征在于，包括：
    芯材；以及
    分布于所述芯材内部的增强体，包括彼此间隔开且交替分布的一个或多个第一增强体和一个或多个第二增强体，其中所述第一增强体和第二增强体横向于增强芯材的长度方向延伸并且所述第一增强体的拉伸模量及拉伸强度分别大于所述第二增强体的拉伸模量及拉伸强度，且所述第一增强体由一种或多种相同或不同形态的纤维经树脂浸润后形成，以及所述第二增强体为高聚物。
  2. 如权利要求1所述的增强芯材，其特征在于，第一增强体的拉伸模量为第二增强体的拉伸模量的150％以上，并且第一增强体的拉伸强度为第二增强体的拉伸强度的150％以上。
  3. 如权利要求1所述的增强芯材，其特征在于，所述纤维包括玻璃纤维和/或碳纤维和/或芳纶纤维和/或天然纤维和/或超高分子量聚乙烯纤维和/或玄武岩纤维。
  4. 如权利要求1所述的增强芯材，其特征在于，所述纤维为织物、短切毡或无纬布的形式。
  5. 如权利要求1所述的增强芯材，其特征在于，所述树脂包括热固性或热塑性树脂。
  6. 如权利要求1所述的增强芯材，其特征在于，所述高聚物包括热固性或热塑性树脂。
  7. 如权利要求1所述的增强芯材，其特征在于，所述芯材的材料为热塑性聚合物或热固性聚合物或含有木纤维的材料或它们的共聚物和混合物。
  8. 如权利要求1所述的增强芯材，其特征在于，所述芯材的第一表面的轮廓为直线形、或波浪形、或锯齿形、或不规则形、或上述任意形状的组合。
  9. 如权利要求1所述的增强芯材，其特征在于，任一所述第一增强体和/或第二增强体与所述芯材的第一表面存在夹角。
  10. 如权利要求9所述的增强芯材，其特征在于，所述第二增强体的高度小于或等于所述芯材的厚度。
  11. 如权利要求1所述的增强芯材，其特征在于，所述第一增强体和/或第二增强体的轮廓为矩形、或三角形、或梯形、或波浪形、或锯齿形、或网格形、或上述任意轮廓的组合。
  12. 如权利要求1所述的增强芯材，其特征在于，任一所述第一增强体及任一所述第二增强体的尺寸和/或形状相同或不同。
  13. 一种制造如权利要求1-12任一所述的增强芯材的方法，其特征在于，包括步骤：
    采用树脂浸润纤维，得到第一增强体；
    将第一增强体与芯材固化，得到预增强芯材；以及
    在所述预增强芯材上形成第二增强体。
  14. 如权利要求13所述的方法，其特征在于，所述第二增强体通过真空灌注、或树脂传递模塑、挤出、注塑、手糊方式制成。
  15. 一种风机叶片，包括主梁、腹板和壳体，所述主梁、腹板和壳体包括夹芯结构和上下蒙皮，其特征在于，所述夹芯结构由一块或多块如权利要求1-12任一所述的增强芯材堆叠形成。
  16. 如权利要求15所述的风机叶片，其特征在于，所述上下蒙皮的材料为玻璃纤维或碳纤维增强的聚合物。
  17. 如权利要求15所述的风机叶片，其特征在于，在平行于叶片弦向的方向上，所述夹芯结构中的第一增强体与第二增强体呈间隔分布。
  18. 如权利要求16所述的风机叶片，其特征在于，在平行于叶片弦向的方向上，相邻两个第一增强体之间的第二增强体的数量为任意整数。
  19. 如权利要求16所述的风机叶片，其特征在于，在平行于叶片弦向的方向上，相邻两个增强体之间的距离相等或不等。
  20. 如权利要求17所述的风机叶片，其特征在于，在平行于叶片长度的方向上，所述夹芯结构中的第一增强体与第二增强体呈间隔分布。
  21. 如权利要求20所述的风机叶片，其特征在于，在平行于叶片长度的方向上，相邻两个第一增强体之间的第二增强体数量为任意整数。
  22. 如权利要求20所述的风机叶片，其特征在于，在平行于叶片长度的方向上，相邻两个增强体之间的距离相等或不等。
PCT/CN2021/114661 2021-08-26 2021-08-26 一种用于风机叶片的增强芯材及其制备方法 WO2023024003A1 (zh)

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