CN108005846A - Main bearing beam for large wind power blades, hybrid spar composite wind power blades and preparation method thereof - Google Patents

Abstract

The invention discloses a main bearing beam for a large wind power blade, which is a combination of carbon fiber/glass fiber hybrid composite round rod profiles, wherein the combination is formed by bundling and shaping a plurality of carbon fiber/glass fiber hybrid composite round rod profiles through glass fiber felts or yarns. The main bearing beam for the large-scale wind power blade adopts the carbon fiber/glass fiber hybrid composite material round rod profile to form a combination body by bunching, makes full use of the complementation of the performances of the carbon fiber and the glass fiber, not only can fully play the advantages of high elasticity and light weight of the carbon fiber, greatly improves the rigidity and the strength of the main bearing beam, increases the critical length of the main bearing beam, but also greatly reduces the price compared with the price of adopting pure carbon fiber as a reinforcing material, and is more beneficial to the popularization and the application of the carbon fiber in the fields of the main bearing beam and the wind power blade. The invention also correspondingly provides a hybrid spar composite wind power blade and a preparation method thereof.

Description

Main bearing beams for large wind power blades, hybrid spar composite wind power blades and their Preparation

technical field

The invention belongs to the field of wind power blade preparation, and in particular relates to a main bearing beam for a large wind power blade, a hybrid spar composite wind power blade and a preparation method thereof.

Background technique

With the improvement of wind turbine blade design technology, large-scale and lightweight has become an important trend in the development of composite wind turbine blades. At present, large-scale composite wind turbine blades mainly use glass fiber as a reinforcing material. However, the development of large-scale blades requires higher and higher strength and stiffness of blades, and the length and self-weight of blades are also increasing, so that glass fiber composite materials cannot bear it. Based on the requirements of large-scale development of blades, light weight and high strength, can effectively increase the critical length of blades, and ensure that the blade tips of the blades do not touch the tower under extreme wind loads. Carbon fiber and its composite materials are the preferred materials. The rigidity of carbon fiber is greater than that of glass fiber, and the addition of carbon fiber can obtain higher rigidity and lighter weight. However, since carbon fiber is much more expensive than glass fiber, this shortcoming limits the widespread use of carbon fiber in large composite wind turbine blades.

In order to reduce costs, good steel is used on the blade, and carbon fiber is used on the main load-bearing spar, blade tip or flange reinforcement of the blade. Related patents such as: WO00/14405 PCT application international publication disclose a wind force A lightning protection device for turbine blades, wherein the arrester is made of one or more flat carbon fiber reinforced plastic strips, and these fiber strips can form a part of the wind turbine blade; CN1697924A Chinese patent document discloses a carbon fiber tip A wind turbine blade with the blade divided into an inner end portion comprising the blade root and substantially made of glass fiber reinforced polymer and an outer end portion comprising the blade tip substantially of carbon fiber reinforced polymer Made; CN101021202A Chinese patent document discloses a carbon fiber reinforced wind turbine rotor blade, the fiber reinforced matrix of the blade includes glass fibers and carbon fibers embedded in the same matrix material.

In addition to the high price of carbon fiber itself, there is still a technical problem in the use of carbon fiber for large wind turbine blades - preparation. At present, the mainstream method of preparing blade aerodynamic shell, main load-bearing spar and shear web is vacuum injection molding process. Sandwich materials such as balsa wood are placed in the forming mold according to the layup design, sealed and vacuumed, and resin infiltrated reinforcing materials are injected to achieve overall molding and stable product quality. However, if the vacuum injection molding process is used to prepare large-thickness carbon fiber or carbon fiber/glass fiber hybrid composite components, such as spars, due to the small diameter of carbon fibers and low surface energy, it is difficult for the resin matrix to fully infiltrate the carbon fibers, and defects are easily formed inside the product. , causing the preparation to fail. However, if the prepreg wet molding process is adopted, not only the preparation cycle is long, the efficiency is low, but also the quality stability is poor. In addition, special equipment such as a prepreg machine is required, and the cost is high.

Contents of the invention

The technical problem to be solved by the present invention is to overcome the deficiencies and defects mentioned in the background technology above, and to provide a main load-bearing beam for wind turbine blades that integrates the properties of carbon fiber and glass fiber, with light weight, extended critical length, and excellent mechanical properties. The excellent large-scale hybrid spar composite wind power blade also provides a preparation method of the composite wind power blade with simple process, strong adaptability and low cost, so as to solve the problem of incomplete or direct carbon fiber impregnation inside the wind power blade in the prior art. Problem with impregnation failure.

In order to solve the above technical problems, the technical solution proposed by the present invention is to provide a main load-bearing beam for large-scale wind power blades, the main load-bearing beam is a combination of carbon fiber/glass fiber hybrid composite round rod profiles, and the combination It is made of several carbon fiber/glass fiber hybrid composite round rod profiles through glass fiber mat or yarn bunching and shaping.

Carbon fiber is a high-performance reinforcing material with excellent performance, which is widely used in aerospace and other fields. Carbon fiber has high specific strength and specific modulus, and is an ideal material for the development of lightweight, high-strength and large-scale composite wind turbine blades, but its high price greatly restricts the application of carbon fiber in the field of wind turbine blades. In order to reduce the quality of large-scale wind power blades, meet the strength and stiffness requirements of the blades, overcome the problem of cost constraints, and solve the technical problems of difficult preparation of large-thickness carbon fiber or carbon fiber/glass fiber hybrid composite materials, the present invention adopts a A new type of reinforced material system, that is, the carbon fiber/glass fiber hybrid composite round bar profile is used for the main load-bearing girder of the wind turbine blade. Due to the specific strength (strength/density) of carbon fiber reinforced composite material (CFRP, Carbon Fiber Reinforced Polymer) It is about 2 times that of GFRP, and the specific modulus (modulus/density) is about 3 times that of GFRP. Therefore, the use of carbon fiber/glass fiber hybrid materials to make wind turbine blades can not only give full play to the advantages of high elasticity and light weight of carbon fiber, but also greatly improve the blade. Rigidity and strength, increase the critical length of the blade, and the price is much lower than using pure carbon fiber as a reinforcing material, which is more conducive to the promotion and application of carbon fiber in the field of wind power blades; at the same time, the carbon fiber/glass fiber hybrid composite round rod profile adopts tensile The automation and continuous production of the extrusion molding process can effectively solve the technical problems of preparation and reduce the preparation cost.

The main load-bearing beam of the present invention is a combination of carbon fiber/glass fiber hybrid composite material round rod profiles, which is formed by bunching of pultruded carbon fiber/glass fiber hybrid composite material round rod profiles, and the diameter of the round rod profiles can be determined according to The size of the spar and the lay-up design can be adjusted arbitrarily, and the bunching combination is directly laid on the shell forming mold, and the shell is laid according to the shape, and it is shaped with glass fiber mat or yarn bunching to make it meet the design requirements of the shell lay-up structure After the laying is completed, the vacuum injection molding process is used together with the shell to form a complete aerodynamic shell, which not only solves the technical problem of difficult preparation of the carbon fiber/glass fiber hybrid composite spar, but also ensures the integrity of the aerodynamic shell. Overall molding. Moreover, the volume ratio of carbon fiber to glass fiber (that is, the mixing ratio) can be adjusted arbitrarily according to the needs of performance and cost. The hybrid ratio can be adjusted arbitrarily, which means that the optimal design of performance can be realized, the hybrid ratio of the spar can be adjusted according to the blade model, and the material cost of carbon fiber can be controlled by adjusting the hybrid ratio.

For the above-mentioned main load-bearing beam, preferably, the carbon fiber/glass fiber hybrid composite round bar profile is a shell-core structure, the core material of the shell-core structure includes carbon fiber, and the shell material includes glass fiber; the transverse direction of the core material The cross-sectional area is 30%~95% of the cross-sectional area of the round bar profile.

The carbon fiber/glass fiber hybrid composite round bar profile is a circular core ring structure in cross-section, carbon fibers are concentratedly distributed inside the round bar to form a round core, and glass fibers are concentratedly distributed outside the round bar to form an outer ring. The diameter, size and ratio of the core and the outer ring can be adjusted arbitrarily according to the needs. The advantage is that the pultruded round rod profile has good conformity and is convenient for laying and shaping. The purpose of concentrated distribution of carbon fiber as the core material is to give full play to the strength and stiffness of carbon fiber, and the purpose of concentrated distribution of glass fiber in the shell material is to give full play to the advantages of glass fiber's corrosion resistance and toughness, which can not only give full play to the mechanical properties of glass fiber. It can also take full advantage of other performance advantages of glass fiber. Moreover, the glass fiber of the outer layer and the glass fiber skin layer of the shell can realize a natural transition, and the adhesion and overall performance are excellent.

Preferably, the carbon fibers are untwisted carbon fiber continuous yarns, and the glass fibers are untwisted glass fiber continuous yarns; the carbon fiber/glass fiber hybrid composite round bar profile is prepared by a pultrusion process.

Based on a general technical idea, the present invention also provides a hybrid spar composite material wind power blade composed of the above-mentioned main bearing beam, the hybrid spar composite material wind power blade includes a suction side shell, a pressure side shell and two The shear web between the shells, the suction side shell, the pressure side shell and the shear web are all sandwich structural members with epoxy resin as the matrix and the skin covering the core material, The core material of the suction side shell and the pressure side shell includes a main bearing beam, a flange reinforcement and a filling material between the main bearing beam and the flange reinforcement.

For the above-mentioned wind turbine blade, preferably, the skins of the suction side shell and the pressure side shell are shell skins, the skin of the shear web is a web skin, and the shell skin and The skin of the web is reinforced with glass fiber; the filling material includes balsa wood and PVC foam, the core material of the shear web is PVC foam, and the reinforcing material of the flange reinforcement is glass fiber yarn Stitched uniaxial fiberglass fabric. In this patent, carbon fiber is not used in the flange reinforcement, only glass fiber is used, the purpose is to further reduce the cost and solve the problem of carbon fiber infiltration difficulty; the filling material includes balsa wood and PVC foam at the same time, and the ratio is determined according to the force characteristics of the blade Yes, the basic principle is to use balsa wood with slightly better density and strength for parts requiring high strength, and PVC foam for parts requiring low strength;

Preferably, the reinforcing material of the web skin includes a triaxially woven glass fiber cloth with an area density of 900-1500g/ ^m2 and a biaxially woven glass fiber cloth with an area density of 600-1000g/ ^m2 (the three-axis After the woven glass fiber cloth and the biaxially woven glass fiber cloth are laid, the vacuum infusion process is used to inject resin to form a composite material and connect the cloth to the cloth); the reinforcing material of the shell skin includes surface density 900-1500g/ ^m2 glass fiber triaxial weaving cloth, glass fiber biaxial weaving cloth with area density 600-1000g/ ^m2 and glass fiber uniaxial weave with area density 1100-1600g/ ^m2 with 50g felt Cloth (after the glass fiber triaxial woven fabric, glass fiber biaxial woven fabric and glass fiber uniaxial woven fabric are laid, the vacuum infusion process is used to inject resin to form a composite material and connect the fabrics) ; The density of the balsa wood is 140-160kg/m ³ , the density of the PVC foam is 50-70kg/m ³ ; the glass fiber used in the flange reinforcement is a belt with an area density of 1100-1600g/m ² 50g felt fiberglass uniaxial cloth.

Based on a general technical concept, the present invention also correspondingly provides a method for preparing a hybrid spar composite material wind turbine blade, comprising the following steps:

(1) The shear web is prepared by vacuum injection molding process;

(2) Using carbon fiber/glass fiber hybrid as a reinforcing material, the carbon fiber/glass fiber hybrid composite material round rod profile for the main bearing beam is prepared by pultrusion process, and the carbon fiber/glass fiber hybrid is obtained by using glass fiber felt or yarn bunching A combination of round bar profiles made of composite materials;

(3) The reinforcing material of the shell skin, the carbon fiber/glass fiber hybrid composite round bar profile for the main bearing beam obtained after the step (2), the filling material and the reinforcing material of the flange reinforcement Layers are laid on the shell forming mold, and the carbon fiber/glass fiber hybrid composite material round rod profile is shaped with glass fiber felt or yarn bunching to obtain a combination of carbon fiber/glass fiber hybrid composite material round rod profiles, which are vacuum introduced after the laying is completed. The suction side shell and the pressure side shell are prepared by molding process, the shear web obtained after the step (1), the suction side shell and the pressure side shell obtained after the step (2) Bonding as a whole to make the hybrid spar composite material wind power blade.

In the above preparation method, preferably, in the step (1), the specific operation of preparing the shear web includes the following steps:

A. Place the cut web skin lower skin reinforcement material, web core material and web skin upper skin reinforcement material in sequence on the web forming mold to obtain a sheared web sandwich structure preform ;

B. Lay the cut-out release cloth on the surface of the shear web sandwich structure preform obtained after the step A, and make it completely cover the pre-form, on the upper surface of the release cloth Lay the auxiliary materials for vacuum injection molding process, and set the injection port and vacuum suction port in the molding cavity;

C. Use a double-layer vacuum bag to seal the preform and auxiliary materials obtained after step B, and evacuate through the vacuum port to make the vacuum degree ≤ -0.098Mpa and keep the vacuum negative pressure not lower than 30min. Then, the epoxy resin system specially used for wind power blades is injected into the mold cavity through the injection port to impregnate the preform by using vacuum negative pressure. -0.098Mpa, until the resin system is completely cured, and the shear web can be obtained after demoulding.

The above-mentioned vacuum injection molding process (also known as vacuum infusion process) used in the preparation of shear webs is an advanced low-cost liquid molding technology for composite materials, which is low-cost, environmentally friendly and suitable for integral molding of large-scale composite components and other advantages, the process principle is to cover the preformed body with a flexible vacuum bag film on the single-sided rigid mold, seal the reinforced material, remove the gas in the mold cavity under vacuum negative pressure, and use the flow and penetration of the resin to realize the resin on the fiber and The fabric is impregnated and cured to form a composite member. Applying the vacuum introduction molding process to the preparation of the composite material wind power blade assembly of the present invention, its advantages can be brought into full play.

Preferably, in the step (2), the specific operation of preparing the carbon fiber/glass fiber hybrid composite round bar profile for the main bearing beam includes the following steps: passing the untwisted carbon fiber continuous yarn and the glass fiber continuous yarn through the bunching tool The carbon fiber is gathered and distributed to form the core of the round rod profile, and the untwisted glass fiber is gathered and distributed around the carbon fiber to form the shell of the core, and then dipped in glue, scraped off the excess glue, and then enters the pultrusion mold for extrusion, curing and shaping. After the mold is pulled out, it is polished to obtain the carbon fiber/glass fiber hybrid composite material round bar profile for preparing the main bearing beam.

The above-mentioned pultrusion molding process used in the preparation of carbon fiber/glass fiber hybrid composite material round rod profiles is a composite material preparation technology that can realize continuous and automatic production. Cloth, etc., under the action of traction, through extrusion die molding, curing, continuous production of unlimited but controllable resin-based composite material profiles. The technology is relatively mature, the product quality is stable, the performance is good, the manufacturing cost is low after a large quantity, and the special extrusion effect in the pultrusion process can well solve the problem of resin infiltration of carbon fiber.

Preferably, the specific operation of the step (3) includes the following steps:

a. On the forming mold of the suction side shell, the reinforcement material of the skin of the suction side shell and the lower skin of the skin, and the carbon fiber/glass fiber hybrid composite round bar profile obtained after the step (2) for the main bearing beam are sequentially laid. Combination body, filling material, reinforcement material of flange reinforcement part and skin reinforcement material on suction surface shell skin, the combination of carbon fiber/glass fiber hybrid composite material round bar profile is shaped by glass fiber mat or yarn bunching , to obtain the suction surface shell preform of the sandwich structure;

b. Lay the cut release cloth on the surface of the suction surface shell preform obtained after the step a, and make it completely cover the preform, and lay a vacuum introduction mold on the upper surface of the release cloth. Plastic process auxiliary materials, and set the plastic injection port and vacuum suction port in the molding cavity;

c. Use a double-layer vacuum bag to seal the preform and auxiliary materials obtained after step b, and evacuate through the vacuum pumping port to make the vacuum degree ≤ -0.098Mpa and keep the vacuum negative pressure not lower than 30min, Then, the epoxy resin system specially used for wind power blades is injected into the mold cavity through the injection port to impregnate the preform by using vacuum negative pressure. -0.098Mpa, until the resin system is completely cured, the suction surface shell is obtained after demoulding, and the pressure surface shell is prepared according to the above method;

d. Bond the suction side shell, pressure side shell and the shear web obtained after the step (1) through the structural adhesive, and the structural adhesive can be obtained after the structural adhesive is cured. Hybrid spar composite wind turbine blade.

Compared with prior art, the beneficial effect of the present invention is:

1. The main load-bearing beam for large-scale wind power blades of the present invention adopts carbon fiber/glass fiber hybrid composite material round rod profiles to form an assembly, fully utilizes the complementary properties of carbon fiber and glass fiber, and can not only give full play to the high elasticity and light weight of carbon fiber Advantages, greatly improve the stiffness and strength of the main load-bearing beam, increase the critical length of the main load-bearing beam, and the price is much lower than using pure carbon fiber as a reinforcing material, which is more conducive to the application of carbon fiber in the field of main load-bearing beams and wind power blades promotion and application.

2. The hybrid wing spar composite material wind power blade of the present invention adopts the combination of carbon fiber/glass fiber hybrid composite material round rod profiles as the main bearing beam, which not only effectively avoids the high cost of pure carbon fiber wind power blades, but also solves the problem of glass fiber The problem of the limitation of the critical length of fiber wind power blades is of great significance for improving the critical length of composite wind power blades and developing large-scale composite wind power blades. It has the advantages of light weight, extended critical length, excellent mechanical properties, and relatively low cost.

3. The preparation method of the present invention not only effectively solves the technical problem of difficult carbon fiber infiltration, ensures the automation, continuity and low cost of hybrid spar production, but also provides a control wing by adjusting the carbon fiber/glass fiber hybrid ratio. The method of beam performance and blade cost is organically integrated with the mainstream mature preparation process of aerodynamic shell and shear web, vacuum import molding process, which reduces the redevelopment and reinvestment of technology and equipment, and the overall process of vacuum import molding process The blade shell is prepared by molding, which has good integrity, can also reduce waste of materials and emission of styrene gas, and is conducive to reducing costs and protecting the environment.

Description of drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following will briefly introduce the drawings that need to be used in the description of the embodiments or the prior art. Obviously, the accompanying drawings in the following description are For some embodiments of the present invention, those skilled in the art can also obtain other drawings based on these drawings without creative work.

Fig. 1 is a cross-sectional schematic diagram of a hybrid composite material pultruded round rod in an embodiment of the present invention;

Fig. 2 is a front view of a composite material wind turbine blade according to an embodiment of the present invention;

Fig. 3 is the sectional enlarged view of A-A place in Fig. 2 of the embodiment of the present invention;

Fig. 4 is the process flowchart of preparing shear web in the embodiment of the present invention;

Fig. 5 is the process flow diagram of the pultruded round rod of the hybrid composite material in the embodiment of the present invention;

Fig. 6 is a process flow chart of forming the suction side shell and the pressure side shell in the embodiment of the present invention.

illustration:

1. Suction side shell; 2. Pressure side shell; 3. Shear web; 31. Web skin; 4. Shell skin; 5. Main bearing beam; 6. Flange reinforcement; 7 ,Filler.

Detailed ways

In order to facilitate the understanding of the present invention, the present invention will be described in more detail below in conjunction with the accompanying drawings and preferred embodiments, but the protection scope of the present invention is not limited to the following specific embodiments.

Unless otherwise defined, all technical terms used hereinafter have the same meanings as commonly understood by those skilled in the art. The terminology used herein is only for the purpose of describing specific embodiments, and is not intended to limit the protection scope of the present invention.

Unless otherwise specified, various raw materials, reagents, instruments and equipment used in the present invention can be purchased from the market or prepared by existing methods.

Example:

A main load-bearing beam for large-scale wind power blades according to the present invention is a combination of carbon fiber/glass fiber hybrid composite material round bar profiles of the main load-bearing beam. The bunching combination is directly laid on the shell forming mold, and the shell is laid according to the shape, and is shaped with glass fiber mat or yarn bunching to make it meet the design requirements of the shell laying structure. After the laying is completed, vacuum is used together with the shell. The molding process is introduced into the whole body to form a complete pneumatic shell. The cross-section of the carbon fiber/glass fiber hybrid composite pultruded rod is shown in Figure 1. In the figure, the core is the carbon fiber accumulation area (core material), and the outer ring is the glass fiber accumulation area (shell material). The fiber is made of untwisted carbon fiber continuous yarn, and the glass fiber is made of untwisted glass fiber continuous yarn.

A hybrid wing spar composite material wind power blade composed of the above-mentioned main load-bearing beam, as shown in Figure 2 and Figure 3, includes a suction side shell 1, a pressure side shell 2 and a shear joint fixed between the two shells. The cut web 3, the base of the suction side shell 1, the pressure side shell 2 and the shear web 3 are all epoxy resin systems, the suction side shell 1 and the pressure side shell 2 are shell skins 4 packs Sandwich type composite material clad with core material, the core material of the suction side shell 1 and the pressure side shell 2 includes the main load-bearing beam 5 of the blade, the flange reinforcement 6 at the edge of the blade for reinforcement and the filler The filling material 7 between the main bearing beam 5 and the flange reinforcement 6, wherein the main bearing beam 5 is a combination of carbon fiber/glass fiber hybrid composite round bar profiles, and the flange reinforcement 6 is stitched with glass fiber yarn The uniaxial fiberglass fabric preform body, the filling material 7 includes Balsa wood and PVC foam; the shear web 3 is also a sandwich structure in which the web skin 31 covers the web core material, and the web core material PVC foam is selected; the reinforcing materials of shell skin 4 and web skin 31 are all selected from glass fiber.

The preparation method of the hybrid spar composite material wind turbine blade described in this embodiment includes the following steps:

1. Preparation of Shear Webs

The preparation process of the shear web 3 is shown in Figure 4, and the specific preparation method includes the following steps in sequence:

1.1 Shear web forming mold pretreatment

Clean up the mold, repair it flat, and then spray a release agent on the surface of the shear web forming mold.

1.2 Cutting and laying web skin reinforcement material and web core material

Select triaxially woven glass fiber cloth with an area density of 1200g/ ^m2 and biaxially woven glass fiber cloth with an area density of 800g/ ^m2 as reinforcement materials for the web skin 31 (upper skin and lower skin), The web core material is PVC foam with a density of 60kg/m ³ . First lay the cut web lower skin reinforcement material on the web forming mold, then lay the cut web core material on the surface of the laid web lower skin reinforcement material, and finally lay the Lay the skin reinforcement material on the web core material on the surface of the web core material to obtain a sheared web sandwich structure preform.

1.3 Cutting and laying release cloth

The release cloth used is the R85PA66 release cloth produced by Shanghai Lek Technology Co., Ltd., with an area density of 85g/m ² . Lay the cut release cloth on the surface of the sheared web sandwich structure preform obtained in step 1.2, and make it completely cover the preform.

1.4 Laying auxiliary material system

On the upper surface of the above-mentioned release cloth, the auxiliary materials for vacuum injection molding process such as guide cloth, guide pipe and air guide pipe are laid, and the glue injection port and vacuum suction port in the mold cavity are set.

1.5 Vacuum bag film sealing

The above-mentioned preform and auxiliary material system were sealed with a double-layer vacuum bag film, and the vacuum bag film used was a Vacfilm400Y26100 vacuum bag film produced by Aerorac, France. First, use the first layer of vacuum bag film to seal the entire preform and auxiliary material system on the mold, seal the injection port and connect the suction port to the vacuum pump, then vacuumize and test the airtightness of the sealed mold cavity (required vacuum degree ≤ -0.098Mpa and can maintain vacuum negative pressure for 30 minutes); after the airtightness of the first layer of vacuum bag film packaging meets the requirements, use the second layer

The vacuum bag film seals the entire first-layer bag film system, and continues to check the airtightness until the airtightness meets the requirements (requires continuous vacuum negative pressure).

1.6 Resin system filling impregnation preform

The resin system used is the blade-specific epoxy resin 1564 and curing agent 3486 system provided by Huntsman; open the injection port to stir evenly and the resin system that has undergone defoaming treatment is injected into the molding cavity by vacuum negative pressure to impregnate the above preformed body , after the resin system is completely impregnated with the preform, close the injection port, and continue vacuuming to maintain the vacuum degree in the molding cavity.

1.7 Curing molding and post-processing

During the curing process, the vacuum degree in the molding cavity must be maintained until the curing is complete. After the curing is completed, post-processing such as demoulding, trimming and cleaning is performed to obtain the shear web member.

2. Hybrid composite round rods for pultruded spars

The process flow of the hybrid composite round bar profile for pultruded wing beams is shown in Figure 5. The specific preparation method includes the following steps in sequence:

2.1 Pretreatment of pultrusion mold

Clean the mold, repair and smooth it, and spray release agent on the surface of the molding cavity.

2.2 Set up bunching tooling and pulling yarn Set up bunching tooling on the pultrusion molding line, draw carbon fiber continuous yarn and glass fiber continuous yarn from the creel through the bunching tooling, so that carbon fibers are preliminarily gathered in the cavity of the pultrusion mold Distribution, the arrangement of glass fibers gathered and distributed around the carbon fibers; then the yarn is drawn through the dipping tank, so that the fiber yarns are covered with resin and the resin is soaked in the fibers.

2.3 Preforming mold positioning and preliminary shaping

The impregnated continuous fiber yarn passes through the preforming mold to scrape off the excess resin glue, giving the yarn a preliminary product shape, and the yarn is further positioned and enters the pultrusion molding mold.

2.4 Pultrusion

After the carbon fiber and glass fiber yarns are positioned and preliminarily shaped in the preforming mold, they are extruded, solidified and finally shaped through the forming mold. The product pulled out from the forming mold is a carbon fiber/glass fiber hybrid composite pultruded round rod. The pulling force of pultrusion is provided by the pulling device.

2.5 post-grinding treatment

The pultruded rod passes through the automatic grinding system under the action of traction, and the release agent on the surface of the pultruded rod is removed from the reel for future use.

3. Molded suction side shell and pressure side shell

The overall molding process flow of the suction side shell 1 and the pressure side shell 2 is shown in Figure 6. The specific preparation method of the suction side shell 1 includes the following procedures (the pressure side shell 2 refers to the preparation process of the suction side shell 1) :

3.1 Shell forming mold pretreatment

Clean the mold, repair it flat, then spray the release agent, and then spray the gel coat.

3.2 Cutting and preparing shell skin reinforcement and core material

According to the design requirements, the skin reinforcement material of the suction surface shell 1, the reinforcement material of the flange reinforcement part 6 and the filling material 7 are cut, and the prefabricated main bearing beam 5 prefabricated in the above steps is trimmed at the same time. The skin reinforcement materials are glass fiber triaxial woven fabric with surface density of 1200g/ ^m2 , glass fiber biaxial woven fabric with surface density of 800g/ ^m2 and glass fiber uniaxial fabric with surface density of 1250g/ ^m2 and 50g mat. Woven cloth (shell skin 4 includes upper skin and lower skin); filling material 7 used includes Balsa wood with a density of 150kg/ ^m3 and PVC foam with a density of 60kg/ ^m3 ; reinforcement material at the flange reinforcement 6 In order to stitch the glass fiber uniaxial fabric, the glass fiber used is a glass fiber uniaxial fabric with an area density of 1250g/m ² and a 50g mat.

3.3 Laying of skin reinforcement materials and core materials

First, lay the lower skin reinforcement material of the suction surface shell 1 on the forming mold of the suction surface shell 1, and then lay the main bearing beam 5 carbon fiber/glass fiber hybrid composite round bar profile at the corresponding position on the surface of the lower skin reinforcement material , filling material 7 (balsa wood and PVC foam prepared in step 3.2) and reinforcement at flange reinforcement 6 (fiberglass fabric prepared in step 3.2); The upper skin reinforcing material of the suction surface casing 1 is laid on top to obtain a preformed body of the suction surface casing 1 with a sandwich structure.

3.4 Cutting and laying release cloth

Lay the cut release cloth (R85PA66 release cloth produced by Shanghai Lek Technology Co., Ltd., with a surface density of 85g/m ² ) on the upper surface of the preformed body of suction surface shell 1 obtained in step 3.3, and make It completely covers the preform.

3.5 Laying auxiliary material system

On the upper surface of the above-mentioned release cloth, the auxiliary materials for the vacuum introduction molding process such as the guide cloth, the guide pipe and the air guide pipe are laid, and the glue injection port and the vacuum suction port are set in the mold cavity.

3.6 Vacuum bag film sealing

A double-layer vacuum bag film is used to seal the preformed body of the suction side shell 1 and the auxiliary material system on the forming mold of the suction side shell. The vacuum bag film used is the Vacfilm400Y26100 vacuum bag film produced by the French Aerorac company. First, use the first layer of vacuum bag film to seal the entire suction surface shell 1 preform and auxiliary material system on the mold, seal the injection port and connect the suction port to the vacuum pump, then vacuumize and test the airtightness of the sealed mold cavity (requires vacuum degree ≤ -0.098Mpa and can maintain vacuum negative pressure for 30 minutes); after the airtightness of the first layer of vacuum bag film packaging meets the requirements, use the second layer of vacuum bag film to seal the entire first layer of bag film system, and Vacuumize and continue to check the airtightness until the airtightness meets the requirements (it is required to be able to maintain the vacuum negative pressure continuously).

3.7 Resin system filling and impregnating suction surface shell preform

The resin system used is the blade-specific epoxy resin 1564 and curing agent 3486 system provided by Huntsman; open the injection port to stir evenly and the resin system that has undergone defoaming treatment is injected into the molding cavity by vacuum negative pressure to impregnate the suction surface shell 1 For the preform, close the injection port after the resin is completely impregnated with the preform, and continue vacuuming to maintain the vacuum in the molding cavity.

3.8 Curing molding and post-processing

During the curing process, the vacuum degree in the molding cavity must be maintained until the curing is complete. After the curing is completed, post-processing such as demoulding, trimming and cleaning is performed to obtain the integrally formed suction surface shell 1 .

The pressure surface casing 2 is then molded according to the above procedures.

In the above-mentioned process, the preparation process of the shear web 3 and the prefabricated main beam 5 can be carried out simultaneously, and the molding preparation process of the suction side shell 1 and the pressure side shell 2 can also be carried out simultaneously.

4. Overall bonding

Adhere the suction surface shell 1, pressure surface shell 2 and shear web 3 prepared in the above steps. The bonding structural adhesive used is the structural adhesive XD4734/XD4735 system provided by Huntsman Company. After the structural adhesive is cured The wind turbine blade made of hybrid spar composite material of the present invention can be obtained after post-processing such as cleaning and trimming.

Claims (10)

1. a kind of wind turbine blade main bearing beam, it is characterised in that the main bearing beam mixes for carbon fibers/fiberglass The assembly of composite material round bar section bar, the assembly is by some carbon fibers/fiberglass hybrid composite round bar section bars Formed by glass mat or the sizing of yarn pack.

2. main bearing beam according to claim 1, it is characterised in that the carbon fibers/fiberglass hybrid composite Round bar section bar is core-shell structure, and the inner nuclear material of the core-shell structure includes carbon fiber, and sheathing material includes glass fibre；It is described The cross-sectional area of inner nuclear material is the 30% ~ 95% of round bar section bar cross-sectional area.

3. main bearing beam according to claim 1 or 2, it is characterised in that the carbon fiber is non-twist carbon fiber continuous yarn, The glass fibre is Non-twisting glass fibre continuous yarn；The carbon fibers/fiberglass hybrid composite round bar section bar uses Pultrusion molding process is prepared.

What 4. a kind of main bearing beam any one of claim 1-3 was formed mixes spar composite material wind electricity blade, its It is characterized in that, the spar composite material wind electricity blade that mixes includes suction surface housing（1）, pressure face housing（2）And two housings Between shear web（3）, the suction surface housing（1）, pressure face housing（2）And shear web（3）It is with epoxy resin The sandwiched structural member formed as matrix and by covering cladding core, the suction surface housing（1）With pressure face housing（2）'s Core includes main bearing beam（5）, edge of a wing strengthening portion（6）With positioned at main bearing beam（5）With edge of a wing strengthening portion（6）Between filling material Material（7）.

5. wind electricity blade according to claim 4, it is characterised in that the suction surface housing（1）With pressure face housing（2） Covering be housing covering（4）, the shear web（3）Covering be web covering（31）, the housing covering（4）And web Covering（31）Using glass fibre as reinforcing material；The packing material（7）Including Ba Sha wood and PVC foams, the shearing abdomen Plate（3）Core be PVC foams, the edge of a wing strengthening portion（6）Reinforcing material be glass fiber yarn suture uniaxially glass Fabric.

6. wind electricity blade according to claim 5, it is characterised in that the web covering（31）Reinforcing material include face Density 900-1500g/m²Three axial weaving fiberglass cloth and surface density 600-1000g/m²Biaxially weaving fiberglass cloth；It is described Housing covering（4）Reinforcing material include surface density 900-1500g/m²The axial woven cloth of glass three, surface density 600- 1000g/m²Glass biaxially woven cloth and surface density 1100-1600g/m²Glass with 50g felts uniaxially woven cloth；It is described The density of Ba Sha wood is 140-160kg/m³, the density of the PVC foams is 50-70kg/m³；The edge of a wing strengthening portion（6）It is used Glass fibre be surface density 1100-1600g/m²Glass with 50g felts uniaxially cloth.

7. a kind of preparation method for mixing spar composite material wind electricity blade as any one of claim 4-6, including such as Lower step：

（1）Shear web is prepared using Vacuum infusion molding process；

（2）Mixed using carbon fibers/fiberglass as reinforcing material, main bearing beam carbon fibre is prepared using pultrusion molding process Dimension/glass fiber hybrid composite material round bar section bar, and shape to obtain carbon fibers/fiberglass with glass mat or yarn pack The assembly of hybrid composite round bar section bar；

（3）By the reinforcing material of housing covering, by the step（2）The main bearing beam obtained afterwards is mixed with carbon fibers/fiberglass The reinforcing material of miscellaneous composite material round bar section bar, packing material and the edge of a wing strengthening portion laying on casing forming mold together, institute State carbon fibers/fiberglass hybrid composite round bar type timber-used glass mat or yarn pack shapes to obtain carbon fiber/glass The assembly of fiber hybrid composite material round bar section bar, prepares the suction using Vacuum infusion molding process after the completion of laying Face-piece body and pressure face housing, by the step（1）Shear web, the step obtained afterwards（2）The suction face-piece obtained afterwards Body and pressure face housing are bonded as one, and are made described and are mixed spar composite material wind electricity blade.

8. preparation method according to claim 7, it is characterised in that the step（1）In, prepare the specific of shear web Operation includes the following steps：

A. covering reinforcing material, web core and web under the web covering cut are laid successively on web molding mould Covering reinforcing material on covering, obtains shear web sandwiched structure preform；

B., the release cloth cut is laid in the shear web sandwiched structure pre-form surface obtained after the step A, And be allowed to that the preform is completely covered, Vacuum infusion molding process auxiliary material is laid with the release cloth upper surface, and set The gum-injecting port and vacuum pumping opening in shaping mold cavity are put；

C. the preform obtained after the step B and auxiliary material are sealed using double-layer vacuum bag film, is taken out by the vacuum Gas port vacuumizes, and makes vacuum≤- 0.098Mpa and negative pressure of vacuum can be kept to be not less than 30min, then that wind electricity blade is special Negative pressure of vacuum is utilized to treat resin system by impregnating preform in the gum-injecting port injection moulding die cavity with epoxy-resin systems Vacuum≤- the 0.098Mpa for keeping shaping mould intracavitary is persistently vacuumized after thorough impregnation preform, until resin system is consolidated Change completely, the shear web is obtained after the demoulding.

9. preparation method according to claim 7, it is characterised in that the step（2）In, prepare main bearing beam carbon fibre The concrete operations of dimension/glass fiber hybrid composite material round bar section bar include the following steps：By non-twist carbon fiber continuous yarn and glass Glass fiber continuous yarn makes carbon fiber Assembled distribution form the kernel of round bar section bar, Non-twisting glass fibre in carbon fibre by pack frock The shell that surrounding Assembled distribution forms kernel is tieed up, impregnation is then carried out, enters pultrusion die after wiping unnecessary glue off, is carried out Extruding, solidifying and setting, polish after molding die pull-out, that is, obtain described preparing main bearing beam carbon fiber/glass fibers Tie up hybrid composite round bar section bar.

10. according to the preparation method any one of claim 7-9, it is characterised in that the step（3）Concrete operations Include the following steps：

A. covering reinforcing material, the step under suction surface housing covering are laid successively on the molding die of suction surface housing （2）Assembly, packing material, the wing of the main bearing beam obtained afterwards carbon fibers/fiberglass hybrid composite round bar section bar Covering reinforcing material on the reinforcing material and suction surface housing covering of edge strengthening portion, the carbon fibers/fiberglass hybrid composite manner Assembly glass mat or yarn the pack sizing of material round bar section bar, the suction surface housing for obtaining sandwiched structure are preforming Body；

B., the release cloth cut is laid in the suction surface housing pre-form surface obtained after the step a, and has been allowed to The all standing preform, Vacuum infusion molding process auxiliary material is laid with the release cloth upper surface, and sets shaping Gum-injecting port and vacuum pumping opening in die cavity；

C. the preform obtained after the step b and auxiliary material are sealed using double-layer vacuum bag film, is taken out by the vacuum Gas port vacuumizes, and makes vacuum≤- 0.098Mpa and negative pressure of vacuum can be kept to be not less than 30min, then that wind electricity blade is special Negative pressure of vacuum is utilized to treat resin system by impregnating preform in the gum-injecting port injection moulding die cavity with epoxy-resin systems Vacuum≤- the 0.098Mpa for keeping shaping mould intracavitary is persistently vacuumized after thorough impregnation preform, until resin system is consolidated Change completely, suction surface housing is obtained after the demoulding, pressure face housing is prepared according to the method described above；

D. suction surface housing, pressure face housing and the step that will be obtained after the step c（1）The shear web obtained afterwards Bonded by structure glue, obtain described mixing spar composite material wind electricity blade after the structure adhesive curing.