Composite material blade, forming combined mold and preparation forming method

Abstract

The invention provides a composite material blade, a forming combined mold and a preparation method. The composite material blade comprises an upper outer layer, a lower outer layer, an inner continuous layer and a filling area, the forming combined mold is used for preparing the composite material blade and comprises a core mold, a cushion layer block, an outer compaction block and a filling strip, and the preparation method comprises the following steps that the outer surface of the core mold is laid with a composite material layer, mold pressing shaping is conducted, and the inner continuous layer is prepared; paving a composite material layer outside the inner continuous layer, and carrying out mould pressing and shaping to prepare one of an upper outer layer and a lower outer layer; paving a composite material layer at the joint of one of the upper outer layer or the lower outer layer and the inner continuous layer, and carrying out mold pressing shaping to prepare a filling area; and paving a composite material layer on the outer sides of the filling area and the inner continuous layer, and carrying out mold pressing shaping to prepare the other one of the upper outer layer and the lower outer layer. According to the method, the composite material blade with good internal densification quality and internal and external molded surface size precision can be simply and efficiently prepared.

Description

Technical Field

[0001] The invention relates to the field of preparation of ceramic-based composite material components, and in particular to the field of preparation methods for blades. Background Art

[0002] Turbine blades are important high-temperature components of gas turbine engines, including Figure 1A The blade body, edge plate and mounting section (or blade root) are shown in the figure. Turbine blades are subjected to very high ambient temperature, centrifugal force and aerodynamic pressure loads in service. At present, turbine blades are mainly made of high-temperature alloy materials, which significantly affects the upper limit of service temperature of turbine blades and the improvement of overall engine performance. Using ceramic matrix composites (CMC) instead of high-temperature alloy materials to prepare turbine blades can give full play to the excellent high-temperature mechanical properties of CMC, significantly improve the upper limit of service temperature of turbine blades and the overall performance of the engine and reduce pollution emissions.

[0003] However, blades made of CMC materials have some disadvantages, such as poor fiber continuity and low overall strength performance. Summary of the invention

[0004] An object of the present invention is to provide a composite material blade.

[0005] Another object of the present invention is to provide a composite material blade forming combined die.

[0006] Another object of the present invention is to provide a method for preparing a composite material blade.

[0007] To achieve the above-mentioned purpose, the composite blade includes an upper outer layer, a lower outer layer, an inner continuous layer and a filling area. The upper outer layer is used to form the blade body surface and the upper surface of the blade edge plate; the lower outer layer is used to form the installation section surface of the blade and the lower surface of the edge plate; the inner continuous layer is located inside the upper outer layer and the lower outer layer, extending from the tip of the blade to the end of the installation section of the blade; the filling area is located at the connection between the upper outer layer, the lower outer layer and the inner continuous layer.

[0008] In one or more embodiments, the composite blade comprises the upper outer layer, the lower outer layer and an inner continuous layer, and the blade further comprises a blade body cavity and a mounting segment filling area located in the inner continuous layer.

[0009] In one or more embodiments, the upper outer layer, the lower outer layer, the inner continuous layer and the filling area are all formed by composite layer materials containing continuous fibers.

[0010] A composite blade forming combination mold for achieving the above-mentioned purpose is used to prepare the above-mentioned composite blade, and the mold includes a core mold, a cushion block, an external compaction block and a filling strip, the outer surface of the core mold is used to provide a draping support surface for the inner continuous layer; the cushion block is detachably wrapped around the outside of the core mold, including a first cushion block in the blade area and a second cushion block in the blade area that are butt jointed with each other, and a first cushion block in the installation section area and a second cushion block in the installation section area that are butt jointed with each other; the external compaction block is detachably wrapped around the outside of the cushion block, including a first compaction block in the blade area and a second compaction block in the blade area that are butt jointed with each other, and a first compaction block in the installation section area and a second compaction block in the installation section area that are butt jointed with each other; the filling strip is detachably arranged between the cushion block and the core mold, and is used to replace the filling area.

[0011] In one or more embodiments, the first compaction block in the blade area, the second compaction block in the blade area, the first compaction block in the installation section area, and the second compaction block in the installation section area are all provided with an extension boss and a connecting hole located on the extension boss, and the combined mold also includes a fixed connecting piece that cooperates with the connecting hole.

[0012] In one or more embodiments, the core mold comprises a removable part, and the removable part is arranged at the blade body of the blade.

[0013] In one or more embodiments, the removable part is a split structure.

[0014] In one or more embodiments, the core mold includes a prefabricated filling part, the composite blade includes a mounting segment filling area, and the prefabricated filling part is used to shape the mounting segment filling area.

[0015] In one or more embodiments, the joints of the first cushion block in the blade area and the second cushion block in the blade area, the first cushion block in the installation section area and the second cushion block in the installation section area, the first compaction block in the blade area and the second compaction block in the blade area, and the first compaction block in the installation section area and the second compaction block in the installation section area are the leading edge and the trailing edge of the blade.

[0016] In one or more embodiments, the filler strip includes a pressure face block and a suction face block abutting against each other.

[0017] A composite blade preparation method for achieving the above-mentioned purpose uses the above-mentioned blade preparation molding combination mold to prepare the above-mentioned composite blade, and the method includes the following steps: S1. Laying a composite material layer on the outer surface of the core mold, performing molding and shaping, and preparing the inner continuous layer; S2. Laying a composite material layer on the outside of the inner continuous layer, performing molding and shaping, and preparing one of the upper outer layer or the lower outer layer; S3. Laying a composite material layer at the connection between one of the upper outer layer or the lower outer layer and the inner continuous layer, performing molding and shaping, and preparing a filling area; S4. Laying a composite material layer on the outer side of the filling area and the inner continuous layer, performing molding and shaping, and preparing the other of the upper outer layer or the lower outer layer.

[0018] In one or more embodiments, the step of preparing the inner continuous layer includes: laying a composite material layer on the outer surface of the core mold, sequentially splicing filling strips, cushioning blocks and external compaction blocks, and using the external compaction blocks for molding to prepare the inner continuous layer.

[0019] After the inner continuous layer is prepared, the prefabricated filling portion is retained.

[0020] The steps of laying the composite material layer are: determining the laying angle, number of layers, and thickness; cutting and patching the composite material layer; and laying and combining the layers layer by layer.

[0021] The method further comprises step S5. separating the formed blade from the composite material blade forming assembly die, and subjecting the formed blade to high temperature carbonization and melt infiltration densification.

[0022] After high-temperature carbonization and melt-infiltration densification are performed on the molded blade, the removable portion located inside the inner continuous layer is removed.

[0023] The composite blade has specific structural characteristics and has good fiber continuity and overall strength performance as a whole, especially in the blade body-edge plate transition area and in the blade height direction.

[0024] The above-mentioned molding combination mold can simply and efficiently complete the preparation and molding of the designed composite material blades. With the help of different assembly forms of the combination mold, through step-by-step paving and compaction shaping, it is ensured that all areas of the working blade have good internal quality and internal and external surface dimensional accuracy.

[0025] The above method can simply and efficiently prepare composite blades with good internal densification quality and internal and external surface dimensional accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The above and other features, properties and advantages of the present invention will become more apparent through the following description in conjunction with the accompanying drawings and embodiments, in which:

[0027] Figure 1A-1BIt is a schematic diagram of the appearance of the turbine blade;

[0028] Figure 1C It is a schematic diagram of the division of each layer of the composite blade;

[0029] Figure 2 It is a schematic diagram of the component disassembly of the composite blade forming combined mold;

[0030] Figure 3 It is a structural schematic diagram of the core mold;

[0031] Figure 4 It is a schematic diagram of the structure of the fill bar;

[0032] Figure 5 It is a schematic diagram of the structure of the cushion block;

[0033] Figure 6 It is a schematic diagram of the structure of the external compaction block;

[0034] Fig. 7A It is a schematic diagram of the state where the composite material layer is laid on the outer surface of the core mold;

[0035] Figure 7B is a schematic diagram when preparing the inner continuous layer;

[0036] Figure 8 It is a schematic diagram of the internal cross-section of the mold when the inner continuous layer is in a molded and finalized state;

[0037] Fig. 9A It is a schematic diagram of the state in which the upper outer layer of the composite material is laid on the outer surface of the inner continuous layer;

[0038] Fig. 9B It is a schematic diagram of the outside and the inside of the mold when the upper outer layer is in the molded state;

[0039] Fig. 10A is a schematic diagram of composite material layers laid up to prepare a fill region and a lower outer layer;

[0040] Fig. 10B It is a schematic diagram of the outside and a cross-sectional diagram of the mold with the filling area and the lower outer layer in the mold closing and compacting state;

[0041] Fig.11 is a flow chart of a composite blade preparation method;

[0042] Fig.12 It is a flow chart of a specific embodiment of a method for preparing a composite blade. DETAILED DESCRIPTION

[0043] The present invention is further described below in conjunction with specific embodiments and drawings. More details are elaborated in the following description to facilitate a full understanding of the present invention. However, the present invention can obviously be implemented in a variety of other ways different from the description herein. Those skilled in the art can make similar generalizations and deductions based on actual application situations without violating the connotation of the present invention. Therefore, the protection scope of the present invention should not be limited by the content of this specific embodiment.

[0044] It should be noted that these and other subsequent drawings are only examples and are not drawn to scale, and should not be used to limit the actual scope of protection required by the present invention.

[0045] Figures 1A to 1C The structural features and drape forming scheme of the designed CMC turbine blade 1 are shown in FIG. The blade 1 comprises a blade body 101, an edge plate 102 and a mounting section 103, wherein the mounting section 103 is also called a blade root. The end of the blade body 101 is a blade tip 105, and the interior of the blade body 101 also has a cavity 104.

[0046] According to the sequence of step-by-step paving, compaction and shaping, the composite blade 1 is divided into an inner continuous layer P1, an upper outer layer P2, a lower outer layer P3, a filling area T1 and an installation section filling area T2, as shown in FIG. Figure 1C shown.

[0047] The upper outer layer P2 is used to form the blade surface and the upper surface where the blade edge plate is connected to the blade surface. The lower outer layer P3 is used to form the mounting section surface of the blade and the lower surface where the edge plate is connected to the root surface. The inner continuous layer P1 is located inside the upper outer layer and the lower outer layer, extending from the tip of the blade to the end of the mounting section of the blade.

[0048] The inner continuous layer P1, the upper outer layer P2 and the lower outer layer P3 are all prepared step by step from a composite material layer containing continuous fibers through processes such as cutting, patching, laying, and molding.

[0049] Specifically, the inner continuous layer P1 is located inside the blade as a whole and extends from the tip 105 area to the bottom end surface of the mounting section 103. The continuous fibers distributed in the inner continuous layer P1 can significantly improve the strength performance of the blade 1 as a whole along the blade height direction and other directions.

[0050] The upper outer layer P2 is located on the surface of the blade body 101 and the upper surface of the edge plate 102, and extends from the blade tip 105 area to the upper surface edge area of ​​the edge plate 102. The continuous fibers in the upper outer layer P2 continuously transition from the blade body area to the edge plate area, which can significantly improve the strength performance of the blade body and the blade body-edge plate transition area of ​​the blade 1.

[0051] The lower outer layer P3 is respectively located on the surface of the mounting section 103 and the lower surface of the edge plate 102, and extends from the bottom end surface of the mounting section 103 to the edge area of ​​the lower surface of the edge plate 102. The continuous fibers in the lower outer layer P3 continuously transition from the mounting section area to the edge plate area, which can significantly improve the strength performance of the mounting section of the blade 1 and the transition area between the mounting section and the edge plate.

[0052] The blade 1 is further divided into a filling area T1 and an installation section filling area T2. The filling area T1 is located at the connection between the upper outer layer P2, the lower outer layer P3 and the inner continuous layer P1, and the installation section filling area T2 is located inside the installation section 103, inside the inner continuous layer P1, and at the bottom of the cavity 104.

[0053] The filling area T1 is located in the transition area between the blade body and the edge plate. Figure 1C In the following description, the filling area T1 will be referred to as a triangle, but those skilled in the art will appreciate that in other embodiments, the filling area T1 may also be in other shapes.

[0054] The triangular filling area T1 is formed by filling with unidirectional continuous fiber composite materials, which is used to fill the annular cavity formed in the transition area between the blade body and the edge plate, improve the compaction degree and surface profile accuracy of the material in the transition area, and improve the densification molding quality and strength performance of the transition area.

[0055] The installation section filling area T2 is formed by filling the prefabricated part of the core mold 5. The solid installation section is conducive to resisting the centrifugal force load and improving the strength performance of the installation section. The above-mentioned draping molding scheme enables the blade 1 to have good overall fiber continuity, thereby significantly improving the overall strength performance, especially the strength performance in the blade height direction and the blade body-edge plate transition area.

[0056] exist Figure 1C In the illustrated embodiment, the height of the installation segment filling area T2 can be changed according to different blade requirements.

[0057] The blade with the above structure has the characteristics of good overall fiber continuity and high strength performance.

[0058] Figure 2 It is a schematic diagram of the disassembly of the components of the molding assembly mold for preparing the above-mentioned CMC turbine blade 1, including the core mold 5, the cushion block 3, the external compaction block 4 and the filling strip 2.

[0059] The filling strip 2 is composed of a pressure surface block 21 and a suction surface block 22, and is used to temporarily replace the filling area T1 during the draping molding process.

[0060] The cushion block 3 includes a first cushion block 31 in the blade area, a second cushion block 32 in the blade area, a first cushion block 33 in the installation section area, and a second cushion block 34 in the installation section area, wherein the first cushion block 31 in the blade area and the second cushion block 32 in the blade area are butt jointed with each other, and the first cushion block 33 in the installation section area and the second cushion block 34 in the installation section area are butt jointed with each other, and are used to temporarily replace and fill the upper outer layer P2 and the lower outer layer P3 during the step-by-step draping and molding of the blade, providing precise paving surfaces and compaction surfaces for accurate shaping and internal compaction of the outer surface of the inner continuous layer P1, the inner surface and the outer surface of the upper outer layer P2 and the lower outer layer P3.

[0061] The external compaction block 4 includes a first compaction block 41 in the blade area, a second compaction block 42 in the blade area, a first compaction block 43 in the installation section area, and a second compaction block 44 in the installation section area, wherein the first compaction block 43 in the installation section area and the second compaction block 44 in the installation section area are butt-jointed with each other, and the first compaction block 41 in the blade area and the second compaction block 42 in the blade area are butt-jointed with each other, which are used for the overall compaction molding of the working blade 1 and the precise molding of the external profile.

[0062] The design and use of the cushion block 3 significantly improves the reuse rate of the external compaction block 4 .

[0063] The outer surface of the core mold 5 provides a paving support surface for the paving of the inner continuous layer P1, and includes a removable portion 51 and a composite material prefabricated filling portion 52. In the subsequent preparation and molding process, the internal cavity of the working blade 1 can be formed by the removable portion 51. The composite material prefabricated filling portion 52 can be retained with other blade areas, such as the upper outer layer P2 and the lower outer layer P3, etc., to form a densified composite material, and then form a solid installation section 103.

[0064] The above-mentioned combined tooling mold for preparation and molding, except for the core mold 5, is in the form of being split in half as a whole. In order to ensure the disassembly and assembly operations, the split joints are set at the leading edge and the trailing edge of the blade 1.

[0065] Below through Figures 3 to 6 The components of the composite blade molding assembly mold are described.

[0066] Figure 3 It is a structural schematic diagram of the core mold 5 located at the innermost part of the combined tooling mold. The shape of the removable part 51 is the same as the blade body cavity 104 of the designed working blade 1, and can be assembled from a combination of removable small pieces of assembly molds. The outer surface of the removable part 51 is used to provide a support surface for the inner continuous layer P1. After preparation, the prefabricated filling part 52 forms a solid installation section 103 of the working blade 1 together with the inner continuous layer P1 and the lower outer layer P3, and can directly form the installation section filling area T2.

[0067] Figure 4: is a schematic diagram of the structure of the filling strip 2, which includes a pressure surface block 21 and a suction surface block 22 that are butted against each other and are detachably arranged between the cushion block 3 and the core mold 5. The filling strip 2 is in the shape of a rotating long strip as a whole, and its cross-sectional shape is approximately triangular, which is the same as the shape of the cavity to be filled formed by paving the blade body-edge plate transition triangle area, and plays a role in replacing and filling the above-mentioned cavity area, mainly providing a paving surface and an internal support compaction surface for the paving shaping of the blade body-edge plate transition area.

[0068] Figure 5 Schematic diagram of the structure of the cushion block 3, the internal cushion block 3 includes an upper left cushion block 31, an upper right cushion block 32, a lower left cushion block 33, and a lower right cushion block 34. In the step-by-step draping molding process, the upper left cushion block 31 and the upper right cushion block 32 are used to replace the upper outer layer P2, and the lower left cushion block 33 and the lower right cushion block 34 are used to replace the lower outer layer P3. The upper left blade surface 312 of the upper left cushion block 31 and the upper right blade surface 322 of the upper right cushion block 32 correspond to the outer blade area, and the upper left edge plate surface 311 of the upper left cushion block 31, the upper right edge plate surface 321 of the upper right cushion block 32, the lower left edge plate surface 331 of the lower left cushion block 33, and the lower right edge plate surface 341 of the lower right cushion block 34 correspond to the upper and lower surface areas of the edge plate. The left lower blade root region 332 of the left lower cushion block 33 and the right lower blade root region 342 of the right lower cushion block 34 correspond to the outer surface of the mounting section 103 .

[0069] The upper left cushion block 31, the upper right cushion block 32, the lower left cushion block 33, and the lower right cushion block 34 are all in the shape of thin sheets as a whole, and have an inner surface N and an outer surface W. Except for the area where the filling strip 2 is located, the inner surface N coincides with the outer surface of the inner continuous layer P1, and the outer surface W coincides with the outer surface of the blade 1.

[0070] Figure 6 It is a schematic diagram of the structure of the external compaction block 4. To achieve assembly compaction, the external compaction block 4 includes an upper left compaction block 41, an upper right compaction block 42, a lower left compaction block 43 and a lower right compaction block 44. Each external compaction block includes an upper left inner profile 411, an upper right inner profile 421, a lower left inner profile 431 and a lower right inner profile 441, which are used to fit and compact the outer profile of the blade 1 in the mold clamping state, thereby shaping the outer profile and improving the internal compaction quality. At the same time, each external compaction block also has a plurality of extension bosses for applying compaction preload, and each extension boss is provided with a connecting hole. Figure 6 The upper left boss 412, the upper right boss 422, the lower left boss 432, and the lower right boss 442 are shown. By passing a fixing connection member such as a mounting bolt through the connection holes on the upper left boss 412, the upper right boss 422, the lower left boss 432, and the lower right boss 442, and tightening nuts, the adjacent external compacting blocks are subjected to compaction preload forces in different directions.

[0071] Combined with the introduction of the above-mentioned composite blades and the combined forming molds, a method for preparing composite blades can also be understood, which is mainly based on the infiltration process of ceramic-based composite prepregs. The method includes the following steps: S1. Laying a composite material layer on the outer surface of the core mold, performing molding and shaping, and preparing an inner continuous layer; S2. Laying a composite material layer on the outside of the inner continuous layer, performing molding and shaping, and preparing one of the upper outer layer or the lower outer layer; S3. Laying a composite material layer at the connection between one of the upper outer layer or the lower outer layer and the inner continuous layer, performing molding and shaping, and preparing a filling area; S4. Laying a composite material layer on the outside of the filling area and the inner continuous layer, performing molding and shaping, and preparing the other of the upper outer layer or the lower outer layer.

[0072] Combine the following FIG. 7A to FIG. 12 This method is further described.

[0073] Figure 7A-7B Schematic diagram of the laying and compaction shaping process of the continuous layer P1 in the CMC turbine blade 1. Fig. 7A The process of laying the inner continuous layer P1 is shown. Figure 7B The compaction and shaping process is shown.

[0074] First, the composite material layer is cut and patched according to the design requirements, and then laid and attached to the outer surface of the core mold 5 layer by layer to achieve the designed laying angle, number of layers and thickness; then, the triangular area filling strip 2, cushion block 3 and external compaction block 4 are installed in the outer area of ​​the inner continuous layer P1 as required, and the inner continuous layer P1 is compacted and the inner and outer surfaces are shaped in cooperation with the core mold 5 to prepare the inner continuous layer P1.

[0075] Figure 8 It is a schematic diagram of the internal cross-section of the mold in the molding state of the continuous layer P1 inside the CMC turbine working blade 1. The upper left compaction block 41, the upper right compaction block 42, the lower left compaction block 43 and the lower right compaction block 44 compact the internal cladding layer together.

[0076] After compaction and shaping is completed, continue as follows Figures 9A-9B Steps shown. Fig. 9A The left side figure shows the first demoulding process, in which the upper left compaction block 41, the upper right compaction block 42, the first cushion block 31 in the blade area, and the second cushion block 32 in the blade area are removed to expose the inner continuous layer P1.

[0077] Fig. 9AThe right side figure shows the paving process of the upper outer layer P2, which is based on the paving surface formed by the outer surfaces of the inner continuous layer P1, the pressure surface block 21, the suction surface block 22, the lower left cushion block 33, and the lower right cushion block 34. The composite layer materials are also cut and patched as required according to the design requirements, and then paved and attached to the above paving surface layer by layer to achieve the design requirements of the ply angle, number of layers and thickness, to complete the paving of the upper outer layer P2.

[0078] Followed by Fig. 9B In the mold closing and compacting process shown, the upper left compacting block 41 and the upper right compacting block 42 are installed again for mold closing and compacting. At this time, there is no need for the first cushion block 31 and the second cushion block 3 in the blade area to temporarily replace the upper outer layer P2 and the lower outer layer P3. The upper outer layer P2 is directly compacted and shaped.

[0079] During the cladding process of the upper outer layer P2, the cladding surface provided by the outer surfaces of the pressure surface block 21 and the suction surface block 22 plays a key supporting role in the cladding shaping and compaction of the upper outer layer P2 in the blade body-edge plate transition area, thereby significantly improving the preparation and molding quality of the working blade 1 in this area. In addition, the continuous fibers contained in the upper outer layer P2 continuously transition from the blade body area to the edge plate area, which significantly improves the strength performance of the blade 1 in this transition area and as a whole. The distribution design of the lower outer layer P3 also has the above technical effects.

[0080] The paving process of the triangular filling area T1 and the lower outer disk is as follows Fig. 10A and 10B shown.

[0081] Fig. 10A The left figure shows the paving state of the triangular filling area T1 after demolding. After P2 is compacted and finalized, the lower left compaction block 43, the lower right compaction block 44, the lower left cushion block 33, the lower right cushion block 34, the pressure surface block 21, and the suction surface block 22 are removed. The paving surface formed by the inner continuous layer P1 and the upper outer layer P2 is paved with a unidirectional composite material according to the design requirements. Figure 1C understand.

[0082] After the filling of the triangular filling area T1 is completed, the lower left cushion block 33, the lower right cushion block 34, the lower left compaction block 43, and the lower right compaction block 44 are used to close the mold again for compaction and shaping, so that the triangular filling area T1 has a regular outer surface that meets the design requirements, thereby providing a good paving surface for the lower outer layer P3 and improving the overall preparation and molding quality.

[0083] Then, the left lower cushion block 33, the right lower cushion block 34, the left lower compaction block 43, and the right lower compaction block 44 are disassembled again, and the lower outer layer P3 is paved with the paving surface formed by the inner continuous layer P1, the upper outer layer P2, and the surface of the triangular filling area T1, as shown in FIG. Fig. 10AAs shown in the right figure, the lower left compacting block 43 and the lower right compacting block 44 are installed again to close the mold and compact and shape the lower outer layer P3, as shown in FIG. Fig. 10B The external schematic diagram and internal cross-sectional view in the mold closing and compacting state are shown.

[0084] At this point, the compaction and shaping of the entire area of ​​the blade 1 is completed. In the above operation process, the lower outer layer P3 can be draped and shaped first, and then the upper outer layer P2 can be draped and shaped.

[0085] The removable part 51 of the core mold 51 is removed to form the blade body cavity 104. The removal operation is performed after the formed blade is separated from the composite blade forming assembly mold, that is, after the blade is integrally laid and low-temperature cured, to prevent the inner continuous layer from deforming and collapsing due to the loss of internal support during the laying molding and curing process. The prefabricated filling part 52 is retained to form the installation section filling area T2.

[0086] Finally, according to the prepreg melt infiltration process, after the formed blade is separated from the composite material blade forming combination mold, the compacted and shaped blade is subjected to high-temperature carbonization and melt infiltration densification, and surface treatment and subtractive processing are carried out according to the design requirements to complete all the manufacturing work of the working blade.

[0087] The above-designed preparation and molding combined mold can simply and efficiently realize the step-by-step paving and compaction shaping of composite materials in different areas of the working blade, and provide precise paving support surfaces and compaction surfaces in each step, so that the working blade has good internal densification quality and internal and external surface dimensional accuracy. The mold is used in coordination with each other in different disassembly and assembly states, and has the characteristics of high utilization rate, simple use method and high efficiency.

[0088] The above method can realize the composite material draping and molding in different areas of the blade, such as the inner continuous layer, upper outer layer, triangular filling area, lower outer layer and prefabricated filling area, by the method of step-by-step draping, compaction and shaping. Based on the precise draping surface and compaction surface provided by the combined mold in different assembly states in each step, it can be ensured that the composite materials in the above-mentioned areas of the blade can be fully compacted and accurately shaped during the draping and molding process. Finally, the prepared blade has good internal quality and surface dimensional accuracy as a whole, without significant internal holes and stratified preparation defects. At the same time, it also has the advantages of simple structure, low difficulty in preparation and molding, and small amount of subtractive processing.

[0089] Although the present invention is disclosed as above with preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art may make possible changes and modifications without departing from the spirit and scope of the present invention. Therefore, any modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention without departing from the content of the technical solution of the present invention shall fall within the protection scope defined by the claims of the present invention.

Claims

1. A composite blade, characterized in that: include: The upper outer layer is used to form the blade body surface and the upper surface of the blade edge plate; A lower outer layer, used to form the mounting section surface of the blade and the lower surface of the edge plate; An inner continuous layer, located inside the upper outer layer and the lower outer layer, extending from the tip of the blade to the end of the mounting section of the blade; as well as A filling area is located at the connection between the upper outer layer, the lower outer layer and the inner continuous layer.

2. The composite blade according to claim 1, characterized in that: The composite material blade comprises the upper outer layer, the lower outer layer and an inner continuous layer, and the blade further comprises a blade body cavity and a mounting section filling area located in the inner continuous layer.

3. The composite blade according to claim 1, characterized in that: The upper outer layer, the lower outer layer, the inner continuous layer and the filling area are all formed by composite layer materials containing continuous fibers.

4. Composite blade forming combined mold, characterized in that: Used to prepare the composite blade according to any one of claims 1 to 3, the mold comprises: A core mold, the outer surface of which is used to provide a draping support surface for the inner continuous layer; The cushion block is detachably wrapped around the outside of the core mold, including a first cushion block in the blade area and a second cushion block in the blade area that are butted against each other, and a first cushion block in the installation section area and a second cushion block in the installation section area that are butted against each other; External compaction blocks are detachably wrapped around the outside of the cushion block, including a first compaction block and a second compaction block in the blade area butted against each other, and a first compaction block and a second compaction block in the installation section area butted against each other; A filling strip is detachably disposed between the cushion block and the core mold to replace the filling area.

5. The composite blade forming combined mold according to claim 4, characterized in that: The first compaction block in the blade area, the second compaction block in the blade area, the first compaction block in the installation section area, and the second compaction block in the installation section area are all provided with an extension boss and a connecting hole located on the extension boss, and the combined mold also includes a fixed connecting piece that cooperates with the connecting hole.

6. The composite blade forming combined mold according to claim 4, characterized in that: The core mold comprises a removable part, and the removable part is arranged at the blade body of the blade.

7. The composite blade forming combined mold according to claim 6, characterized in that: The removable part is a split structure.

8. The composite blade forming combined mold according to claim 6, characterized in that: The core mold includes a prefabricated filling part, the composite material blade includes a mounting section filling area, and the prefabricated filling part is used to shape the mounting section filling area.

9. The composite blade forming combined mold according to claim 4, characterized in that: The joints of the first cushion block and the second cushion block in the blade area, the first cushion block and the second cushion block in the installation section area, the first compaction block and the second compaction block in the blade area, and the first compaction block and the second compaction block in the installation section area are the leading edge and the trailing edge of the blade.

10. The composite blade forming combined mold according to claim 4, characterized in that: The filling strip includes a pressure face block and a suction face block that abut against each other.

11. A method for preparing a composite blade, characterized in that: The composite blade according to any one of claims 1 to 3 is prepared using the blade preparation and molding assembly mold according to any one of claims 4 to 10. The method comprises the following steps: S1. Covering the outer surface of the mandrel with a composite material layer, performing molding and shaping to prepare the inner continuous layer; S2. The composite material layer is covered on the outer surface of the inner continuous layer, and the molding is performed to prepare one of the upper outer layer or the lower outer layer; S3. A composite material layer is laid at the junction of one of the upper outer layer or the lower outer layer and the inner continuous layer, and molded to prepare a filling area; S4. Laying a composite material layer on the outer side of the filling area and the inner continuous layer, performing molding and shaping, and preparing the other of the upper outer layer or the lower outer layer.

12. The method for preparing a composite blade according to claim 11, characterized in that: The steps of preparing the inner continuous layer include: The composite material layer is spread on the outer surface of the core mold, and the filling strips, cushion blocks and external compaction blocks are spliced ​​in sequence. The external compaction blocks are used for molding and shaping to prepare the inner continuous layer.

13. The method for preparing a composite blade according to claim 11, characterized in that: After the inner continuous layer is prepared, the prefabricated filling portion is retained.

14. The method for preparing a composite blade according to claim 11, characterized in that: The steps of laying the composite material layer are: determining the laying angle, number of layers, and thickness; cutting and patching the composite material layer; and laying and combining the layers layer by layer.

15. The method for preparing a composite blade according to claim 11, characterized in that: The method further comprises step S5. separating the formed blade from the composite material blade forming assembly die, and subjecting the formed blade to high temperature carbonization and melt infiltration densification.

16. The method for preparing a composite blade according to claim 15, characterized in that: After the formed blade is separated from the composite material blade forming combined mold, the removable part located inside the inner continuous layer is removed, and then high-temperature carbonization and melt infiltration densification treatment are performed.

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