Mold, molding method, double-web structure, blade, and wind turbine generator system

Abstract

The application relates to a mold, a forming method, a double-web structure, a blade and a wind turbine generator set, wherein the mold comprises a lower mold provided with a first cavity; an upper mold capable of being buckled with the lower mold and forming a closed hollow cavity; a core mold capable of being arranged in the hollow cavity, the core mold comprising an elastomer and a vacuum bag group, the elastomer being filled in the vacuum bag group, the volume of the elastomer being capable of being shrunk or reduced along with the change of air pressure in the vacuum bag group, and the vacuum bag group being provided with an openable and closable interface. The mold provided by the application can form the double-web structure at one time, improves production efficiency and reduces production cost.

Description

Technical Field

[0001] This application relates to the field of wind power generation technology, and in particular to a mold, molding method, double web structure, blade, and wind turbine generator set. Background Technology

[0002] In the current wind power generation field, to improve the overall strength of wind turbine blades, a common method is to install webs inside the blades for support. Each blade can have a double-web structure consisting of a leading-edge web and a trailing-edge web to provide better support. Currently, the leading-edge and trailing-edge webs are typically manufactured and processed separately, then aligned and assembled on tooling, and finally bonded to the blade skin. This process requires specialized alignment and assembly tooling, which occupies a large area, and the bonding and curing between the webs takes a long time, leading to reduced overall blade production efficiency and increased production costs. Furthermore, when bonding the assembled double-web structure to the skin, adhesive easily overflows from the flanges and enters the gap between the leading and trailing-edge webs. Due to space limitations, cleaning and reinforcing this overflowing adhesive is difficult, further reducing production efficiency.

[0003] Therefore, there is an urgent need for a mold and corresponding molding method that can improve the production efficiency of web plates and reduce costs, as well as double web plate structures, blades and wind turbine generator sets. Summary of the Invention

[0004] This application provides a mold, a forming method, a double-web structure, a blade, and a wind turbine generator set. The mold is used to form the double web of the blade, which can improve the production efficiency of the double web and reduce the cost.

[0005] In a first aspect, according to an embodiment of this application, a mold is provided for forming a double web of a blade. The mold includes: a lower mold having a first cavity; an upper mold capable of engaging with the lower mold to form a closed hollow cavity; and a core mold capable of being disposed in the hollow cavity. The core mold includes an elastomer and a vacuum bag assembly. The elastomer is filled within the vacuum bag assembly, and the volume of the elastomer can shrink or expand with changes in air pressure within the vacuum bag assembly. The vacuum bag assembly has an openable and closable interface.

[0006] According to one aspect of the embodiments of this application, a vacuum bag assembly includes two or more vacuum bag bodies, the two or more vacuum bag bodies are stacked and arranged, and at least the outermost vacuum bag body has an interface; the vacuum bag assembly is capable of switching between a first state and a second state, in the first state, the vacuum bag assembly is in contact with an elastomer; in the second state, there is a gap between the outermost vacuum bag body and the elastomer.

[0007] According to one aspect of the embodiments of this application, the elastomer includes at least one of sponge, foam, and rubber.

[0008] According to one aspect of the embodiments of this application, the elastomer includes a plurality of sub-elastomers, which are connected to each other.

[0009] According to one aspect of the embodiments of this application, the distance between the orthographic projection of the core mold at the bottom of the first cavity and the distance between the two sidewalls of the first cavity extending along its own length direction are equal.

[0010] According to one aspect of the embodiments of this application, the lower mold further includes a lower mold flange, and the first cavity is provided with lower mold flanges on both sides of its own width direction. The upper mold includes a second cavity and an upper mold flange, and the second cavity is provided with upper mold flanges on both sides of its width direction. The upper mold flange and the lower mold flange can be sealed and connected, and the first cavity and the second cavity are connected to form a hollow cavity.

[0011] According to one aspect of the embodiments of this application, the first cavity and the second cavity have opposite recessing directions and the same recessing depth.

[0012] According to one aspect of the embodiments of this application, the height of the core mold in the recessed direction of the first cavity is greater than the recessed depth of the first cavity.

[0013] According to one aspect of the embodiments of this application, the mold further includes a heating system disposed on the lower mold and the upper mold, and the heating system is capable of heating the hollow cavity.

[0014] Secondly, according to embodiments of this application, a molding method is proposed for molding a double-web structure, comprising: providing a mold as described in any embodiment of the first aspect; laying a ply structure in a lower mold, the ply structure including a first ply, a second ply, and a first core material sandwiched between the first ply and the second ply, the first core material being disposed in a first cavity and forming a main body together with the portions of the first ply and the second ply located in the first cavity, the first ply and the second ply both extending at least partially outside the first cavity and the portions extending outside the first cavity together forming an extension; placing a core mold in the first cavity and stacking it with the main body; folding the extension back and disposing a second core material between the first ply and the second ply covering the core mold, the extension overlapping with the main body to form a closed loop; fastening the upper mold and the lower mold together internally to form a whole to be infused; vacuuming the whole to be infused, infusing resin, and curing; separating the lower mold and the upper mold and extracting the elastomer to form a double web.

[0015] According to one aspect of the embodiments of this application, the step of laying a ply structure in a lower mold includes: laying a first ply on the lower mold, the first ply including a first region covering a first cavity and a second region extending out of the first cavity; laying a first core material in the first region; laying a second ply on the first core material and the second region, the second ply including a third region covering the first core material and a fourth region covering the second region.

[0016] According to one aspect of the present application, the step of folding back the extension and placing a second core material between the first ply and the second ply covering the core mold includes: folding back and laying the fourth region of the second ply so that the fourth region covers the core mold; laying the second core material on the side of the fourth region of the second ply away from the core film; and folding back and laying the second region of the first ply so that the second region covers the second core material.

[0017] According to one aspect of the present application, prior to the step of separating the lower mold and the upper mold and extracting the elastomer to form a double web, the forming method further includes: suctioning the interior of a vacuum bag assembly to reduce the volume of the elastomer.

[0018] According to one aspect of the present application, before the step of placing the core mold in the first cavity and stacking it with the main body, the molding method further includes: providing a guide net and a flow channel between the core mold and a portion of the second layup located in the main body.

[0019] According to one aspect of the present application, after the step of separating the lower mold and the upper mold and extracting the elastomer to form a double web, the forming method further includes: removing the vacuum bag assembly that is attached to the inner surface of the double web.

[0020] Thirdly, according to the embodiments of this application, a double-web structure is proposed, which is manufactured by the molding method in any embodiment of the second aspect. The double-web structure includes: a front edge web, a first connecting part, a rear edge web, and a second connecting part. The front edge web, the first connecting part, the rear edge web, and the second connecting part are connected end to end in sequence to form a closed ring and are integrally molded.

[0021] Fourthly, according to the embodiments of this application, a blade is proposed for use in a wind turbine generator set, including the double web structure proposed in the third aspect.

[0022] Fifthly, according to embodiments of this application, a wind turbine generator set is provided, comprising at least one blade as described in the fourth aspect.

[0023] This application provides a mold for forming a double web of a blade. The mold includes a lower mold and an upper mold that can be interlocked to form a hollow cavity, and a core mold disposed in the hollow cavity. The core mold includes an elastic body fitted with a vacuum bag assembly. By controlling the air pressure difference inside and outside the vacuum bag assembly, the shape of the vacuum bag assembly can be changed to assist in the forming of the web from the inside. Furthermore, the upper mold and the lower mold provided in this application can form an annular sealed cavity after interlocking, thereby forming a complete double web structure in one step. It is not necessary to assemble the web after demolding, which can effectively simplify the process, reduce costs and improve production efficiency. Attached Figure Description

[0024] The features, advantages, and technical effects of exemplary embodiments of this application will now be described with reference to the accompanying drawings.

[0025] Figure 1 This is a partial structural schematic diagram of the mold provided in an embodiment of this application;

[0026] Figure 2 This is a partial structural schematic diagram of the lower mold provided in an embodiment of this application;

[0027] Figure 3 This is a partial structural schematic diagram of the core mold provided in an embodiment of this application;

[0028] Figure 4 This is a flowchart of the molding method provided in the embodiments of this application;

[0029] Figure 5 yes Figure 4 A schematic diagram of the structure corresponding to step S2 of the molding method shown;

[0030] Figure 6 yes Figure 4 A schematic diagram of the structure corresponding to step S4 of the molding method shown;

[0031] Figure 7 yes Figure 4 A schematic diagram of the structure corresponding to step S5 of the molding method shown;

[0032] Figure 8 This is a partial flowchart of the molding method provided in the embodiments of this application;

[0033] Figure 9 This is a partial flowchart of the molding method provided in the embodiments of this application;

[0034] Figure 10 This is a schematic diagram of the double web structure provided in the embodiments of this application;

[0035] Figure 11 This is a schematic diagram of the blade structure provided in an embodiment of this application;

[0036] Figure 12 This is a schematic diagram of the structure of the wind turbine generator set provided in the embodiments of this application.

[0037] in:

[0038] 100 - Mold; 200 - Double web structure; 300 - Blade; 400 - Wind turbine generator set;

[0039] 10-Lower mold; 20-Upper mold; 30-Hollow cavity; 40-Core mold; 50-Layer structure; 60-Leading edge web; 70-First connecting part; 80-Rearing edge web; 90-Second connecting part;

[0040] 11-First cavity; 12-Lower mold flange; 21-Second cavity; 22-Upper mold flange; 41-Elastomer; 42-Vacuum bag assembly; 51-First layup; 52-Second layup; 53-First core material; 54-Main body; 55-Extension; 56-Second core material;

[0041] 421 - Vacuum bag body; 511 - Zone 1; 512 - Zone 2; 521 - Zone 3; 522 - Zone 4;

[0042] X - Length direction; Y - Width direction; Z - Thickness direction.

[0043] In the accompanying drawings, the same parts use the same reference numerals. The drawings are not drawn to scale. Detailed Implementation

[0044] The features and exemplary embodiments of various aspects of this application will now be described in detail. Numerous specific details are set forth in the following detailed description to provide a comprehensive understanding of this application. However, it will be apparent to those skilled in the art that this application can be implemented without requiring some of these specific details. The following description of embodiments is merely intended to provide a better understanding of this application by illustrating examples. In the accompanying drawings and the following description, at least some well-known structures and techniques are not shown to avoid unnecessarily obscuring the application; and, for clarity, the dimensions of some structures may be exaggerated. Furthermore, the features, structures, or characteristics described below can be combined in any suitable manner in one or more embodiments.

[0045] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, "multiple" means two or more, and the terms "installation" and "connection" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to direct connections or indirect connections. The terms "upper," "lower," "left," "right," "inner," and "outer," etc., indicate orientation or positional relationships only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0046] Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Those skilled in the art will understand the specific meaning of these terms in this application based on the specific circumstances.

[0047] In the current field of wind power technology, to obtain maximum wind power, wind turbines are usually installed in relatively remote locations, resulting in high maintenance costs. Therefore, improving blade strength is one of the key design considerations for wind turbines. Existing wind turbine blades typically use webs to ensure strength. These webs can be a single, separate piece, or a double-web structure consisting of a leading-edge web and a trailing-edge web can be used to further enhance strength. When using a double-web structure, the current manufacturing method typically involves casting the two webs separately, then aligning and assembling them on specialized assembly fixtures. After assembly, further cleaning and reinforcement work is required.

[0048] Based on this, the inventors discovered that existing double-web structure assembly requires specific tooling, occupies a large area, and takes a long time for bonding and curing. Furthermore, when bonding the assembled double webs to the blade skin, adhesive will squeeze out from the gap between the two webs, requiring manual cleaning after bonding. However, the gap between the webs is small, making cleaning difficult. In addition, reinforcement work is required at the bonding point between the web flange and the skin, further reducing production efficiency. Ultimately, this results in low production efficiency and high production cost for the double-web structure.

[0049] To address the aforementioned issues, this application proposes a mold for forming a double-web structure. This mold can form a complete double-web structure in one step, eliminating the need to assemble the leading and trailing webs, thereby effectively improving production efficiency and reducing production costs. Furthermore, the double-web structure integrally formed by this mold can mitigate the problem of adhesive overflowing from the gaps between the webs during bonding with the blade skin, thus eliminating the need for cleaning excess adhesive and further improving production efficiency.

[0050] It is understood that the following embodiments of this application are only used as examples of processing a double-web structure for wind turbine blades using the mold provided in this application. However, the application of the mold provided in the embodiments of this application is not limited to the following embodiments. It can also be used to form plate-shaped structures applied in other fields and to protect them.

[0051] To better understand this application, the following will be combined with... Figures 1 to 12 The mold, molding method, double web structure, blade and wind turbine generator set of the embodiments of this application are described in detail.

[0052] Please refer to the following: Figures 1 to 3 , Figure 1 This is a partial structural schematic diagram of the mold provided in an embodiment of this application. Figure 2 This is a partial structural schematic diagram of the lower mold provided in an embodiment of this application. Figure 3 This is a partial structural schematic diagram of the core mold provided in the embodiments of this application.

[0053] In a first aspect, embodiments of this application propose a mold 100 for forming the double web of a blade. The mold 100 includes a lower mold 10, an upper mold 20, and a core mold 40. The lower mold 10 has a first cavity 11. The upper mold 20 can be fastened with the lower mold 10 to form a closed hollow cavity 30. The core mold 40 is disposed in the hollow cavity 30 and includes an elastomer 41 and a vacuum bag assembly 42. The elastomer 41 is filled in the vacuum bag assembly 42. The volume of the elastomer 41 can shrink or expand with the change of air pressure in the vacuum bag assembly 42. The vacuum bag assembly 42 has an openable and closable interface.

[0054] Optionally, the mold 100 provided in this embodiment has a lower mold 10 and an upper mold 20 that can be fastened together, forming a closed hollow cavity 30. A core mold 40 is disposed within the hollow cavity 30. It is understood that referring to the hollow cavity 30 as "closed" means that the hollow cavity 30 is closed in its circumferential direction, while at least one of its two ends along its length direction X has an opening to facilitate vacuuming and other processes necessary for forming the double-web structure. For example, during use, a vacuum tube can be inserted through the opening to connect the hollow cavity to a vacuum pump, thereby evacuating the required location within the hollow cavity. Simultaneously, multiple injection ports can be spaced along the length of the upper and lower molds. After vacuuming and pressure holding, the injection material can be injected through the injection ports and cured by heating to form the double web structure.

[0055] Optionally, the lower mold 10 has a first cavity 11. After being engaged with the upper mold 20, the two work together to form a circumferentially closed hollow cavity 30. Based on this, the upper mold 20 can have a cavity corresponding to the lower mold 10, and the cavities of the lower mold 10 and the upper mold 20 are arranged opposite to each other to form the hollow cavity 30. Alternatively, the upper mold 20 can also be a capping mold, that is, the upper mold 20 covers the opening of the first cavity 11 in the form of a cover plate, so that the first cavity 11 is closed in the circumferential direction, thereby forming the hollow cavity 30. This application does not make specific limitations on this, as long as the two can form a circumferentially closed cavity after being engaged and match the thickness of the required double web.

[0056] Optionally, the core mold 40 in this embodiment includes an elastomer 41 and a vacuum bag assembly 42 sleeved outside the elastomer 41. The core mold 40 is disposed in the hollow cavity 30, and there can be a certain gap between the circumferential sidewall of the core mold 40 and the circumferential sidewall of the hollow cavity 30. When using the mold 100, the materials required for forming the front edge web and the rear edge web can be respectively disposed between the core mold 40 and the lower mold 10 and between the core mold 40 and the upper mold 20. Therefore, there are certain requirements for the size of the aforementioned gaps. That is, in the thickness direction Z, the gap between the core mold 40 and the hollow cavity 30 needs to be greater than or equal to the thickness of the web. In the width direction Y, the size of the gap between the core mold 40 and the hollow cavity 30 needs to be able to form two connecting parts that connect the two webs together.

[0057] Optionally, the vacuum bag assembly 42 in this embodiment has an openable and closable interface. During the use of the mold 100, the interior of the vacuum bag assembly 42 can be connected to the external atmospheric pressure environment through the interface, so that the interior of the vacuum bag assembly 42 is kept at normal pressure. This ensures that at least the outermost vacuum bag assembly 42 can expand when the hollow cavity 30 is evacuated, and presses the substrate for forming the web, which is placed around the mandrel 40, onto the cavity wall of the hollow cavity 30, so as to facilitate subsequent infusion and curing. It can be understood that by adjusting the shape and size of the vacuum bag assembly 42 after expansion, the shape and size of the gap in the middle of the double web structure to be formed can be affected accordingly. By adjusting the shape of the cavity wall of the hollow cavity 30, the shape of the outer wall of the web to be formed can be adjusted accordingly. By comprehensively adjusting the shape of the cavity wall of the hollow cavity 30, the thickness of the web substrate surrounding the mandrel 40, and the shape and size of the vacuum bag assembly 40, an integrally formed double web of the desired shape can be obtained.

[0058] Furthermore, the core mold 40 consists of an elastomer 41 and a vacuum bag assembly 42 fitted onto the elastomer 41. By evacuating the vacuum bag assembly 42 to compress it, the volume of the elastomer 41 can be compressed, reducing its overall volume and facilitating subsequent demolding after injection and curing.

[0059] The mold 100 provided in this application embodiment can form a complete double web structure in one step, eliminating the need to assemble the webs after demolding, which can effectively simplify the process, reduce costs and improve production efficiency.

[0060] In some optional embodiments, the vacuum bag assembly 42 includes two or more vacuum bag bodies 421, which are stacked and at least the outermost vacuum bag body 421 has an interface; the vacuum bag assembly 42 is switchable between a first state and a second state, in which the vacuum bag assembly 42 is in contact with the elastomer 41; in the second state, there is a gap between the outermost vacuum bag body 421 and the elastomer 41.

[0061] The vacuum bag assembly 42 provided in this embodiment can be composed of multiple layers of vacuum bag bodies 421 nested together. Optionally, taking a vacuum bag assembly 42 comprising two layers of vacuum bag bodies 421 as an example, the outer vacuum bag body 421 is provided with an interface, while the inner vacuum bag body is attached to the elastomer 41. During the use of the mold 100, the interface is connected to the external normal pressure environment, so that the interior of the vacuum bag assembly 42 maintains a normal pressure environment. In the first state, before the hollow cavity 30 is evacuated, the entire vacuum bag assembly 42 is supported by the elastomer 41 and fits against the surface of the elastomer 41. In the second state, when the hollow cavity 30 needs to be evacuated during use, the outer vacuum bag 421 expands outward and creates a gap between it and the inner vacuum bag 421. Finally, the outer vacuum bag 421 comes into contact with the material for forming the web in the hollow cavity 30 and presses it against the inner walls of the upper mold 20 and the lower mold 10. Therefore, the shape of the outer vacuum bag 421 after expansion should match the gap between the two webs in the double-web structure to be formed.

[0062] Meanwhile, in both the first and second states, the inner vacuum bag 421 covers the elastomer 41. When demolding the double web after the injection molding is completed, the inside of the inner vacuum bag 421 can be vacuumed, which can reduce the size of the inner vacuum bag 421 accordingly. This causes the elastomer 41 placed inside the vacuum bag assembly 42 to be compressed and its volume reduced, making it easier for the elastomer 41 to be extracted from the gap in the middle of the double web structure, which also facilitates the demolding of the core mold 40.

[0063] Optionally, taking the vacuum bag assembly 42 as an example, which includes two layers of vacuum bag bodies 421, both of these layers of vacuum bag bodies 421 can be provided with interfaces. That is, during the injection molding process, the external normal pressure environment can be connected to the interface of the inner vacuum bag body 421 through the vacuum tube passing through the interface of the outer vacuum bag body 421, so that the interior of the inner vacuum bag body 421 is kept at normal pressure. At this time, in the second state, when the hollow cavity 30 is evacuated, the interior of the vacuum bag assembly 42 is at normal pressure, and the exterior is in a vacuum environment. This allows both layers of vacuum bag bodies 421 in the vacuum bag assembly 42 to expand outward and press the web substrate tightly against the cavity wall of the hollow cavity 30.

[0064] Meanwhile, after the injection is completed, the aforementioned vacuum tube can be directly connected to the vacuum pump to evacuate the inside of the inner vacuum bag 421, causing the elastomer 41 to shrink and achieve the function of easy demolding.

[0065] It is understood that the vacuum bag assembly 42 may also be provided with more layers of vacuum bag bodies 421. These vacuum bag bodies are divided into two groups: an inner layer group and an outer layer group, which perform the same function as the aforementioned inner layer vacuum bag body 421 and outer layer vacuum bag body 421 respectively. Only the vacuuming position needs to be adjusted adaptively. This application does not make any specific limitations on this.

[0066] When using two or more vacuum bag bodies 421, the interface with the normal pressure environment can be located on the innermost vacuum bag body 421 of the outermost group. Correspondingly, the vacuum interface for evacuating the space where the elastomer 41 is located can be located on the outermost vacuum bag body 421 of the innermost group. This allows the two groups of vacuum bag bodies 421 to perform their respective functions. Using a multi-layer vacuum bag group 42 can improve structural strength and prevent the failure of a certain vacuum bag body 421 from causing the corresponding function to fail. When using the mold 100 provided in the embodiments of this application, it can be designed according to usage requirements and other conditions.

[0067] In some alternative embodiments, the elastomer 41 includes at least one of sponge, foam, and rubber.

[0068] In this embodiment, the elastomer 41 is an important component of the core mold 40. The elastomer 41 fills the interior of the aforementioned vacuum bag assembly 42 and supports it. Therefore, in addition to being elastic and compressible, the elastomer 41 should also possess a certain strength to support the weight of the vacuum bag assembly 42 and the web core material required for molding without significant deformation. Thus, the elastomer 41 can be made of materials that combine elasticity and a certain degree of hardness, such as foamed rubber or foamed sponge.

[0069] In some alternative embodiments, the elastomer 41 includes a plurality of sub-elastomers, which are connected in series.

[0070] In existing wind turbine units, the blades are relatively long, and the webs are correspondingly long. In this embodiment, the elastomer 41 extends along the length direction X of the web, so the elastomer 41 also has a certain length. When the length is greater than a certain value, multiple sub-elastomers can be connected together to form a complete elastomer 41 along the length direction X. The outline shape of the elastomer 41 should match the outline shape of the gap area in the middle of the double webs to be formed. Based on this, the distances that the multiple sub-elastomers extend in the length direction X can be the same or different. Setting the multiple sub-elastomers to the same length makes the sub-elastomers easier to process.

[0071] It is understandable that the materials of multiple sub-elastic bodies can be the same or different. The width of the double web structure applied in wind turbine blades varies with the height of the blade. Therefore, along the length direction X, the width and weight of the core material set in the double web structure at different positions are also different. Therefore, when setting the sub-elastic bodies, a harder material can be used in the heavier parts of the core material and a softer material can be used in the lighter parts of the core material. This application does not make specific limitations in this regard, as long as it is ensured that the elastomer 41 will not undergo severe deformation under the weight of the core material and the vacuum bag assembly 42.

[0072] In some alternative embodiments, the orthographic projection of the core mold 40 at the bottom of the first cavity 11 is equal to the distance between the two sidewalls of the first cavity 11 extending along its own length direction X.

[0073] In this embodiment, the core mold 40 is disposed in the first cavity 11 of the mold 10, and both the core mold 40 and the first cavity 11 extend in the same direction. Therefore, the orthographic projection of the core mold 40 on the bottom plane of the first cavity 11 should fall entirely within the contour range of the first cavity 11. Based on this, the distance between the orthographic projection of the core mold 40 and the two side walls of the first cavity 11 can be equal, that is, the distance between the opposite side walls of the core mold 40 and the opposite side walls of the first cavity 11 is equal. This allows the double web structure 200 formed using the mold 100 to have connecting parts of the same thickness, that is, the thickness of the two connecting parts connecting the front edge web 60 and the rear edge web 80 is the same, thereby making the support force provided by the double web structure 200 more uniform.

[0074] In some optional embodiments, the lower mold 10 further includes a lower mold flange 12, and the first cavity 11 is provided with lower mold flanges 12 on both sides of its width direction Y. The upper mold 20 includes a second cavity 21 and an upper mold flange 22, and the second cavity 21 is provided with upper mold flanges 22 on both sides of its width direction Y. The upper mold flange 22 and the lower mold flange 12 can be sealed together, and the first cavity 11 and the second cavity 21 are connected to form a hollow cavity 30.

[0075] The mold 100 in this embodiment includes a lower mold 10 and an upper mold 20 that engage. As mentioned earlier, both the lower mold 10 and the upper mold 20 may have cavities, which are arranged opposite each other and combined to form a hollow cavity 30. Alternatively, the upper mold 20 may be used to close the opening of the first cavity 11, thereby forming a circumferentially closed hollow cavity 30. Based on this, in order to facilitate demolding of the double web after injection molding, both the lower mold 10 and the upper mold 20 may be configured to have cavities, and flanges may be provided on both sides in the width direction Y of the cavities to securely connect and fix the lower mold 10 and the upper mold 20. When the lower mold 10 and the upper mold 20 have the first cavity 11 and the second cavity 21 respectively, the two cavities combine to form a hollow cavity 30. In this case, during the demolding process, after the upper mold 20 is removed, the double web structure is at least partially exposed outside the lower mold 10, thereby making it easier to remove the molded double web. The height of the double webs exposed outside the first cavity 11 can be adjusted by adjusting the parting surface between the lower mold 10 and the upper mold 20.

[0076] Optionally, the lower mold 10 has lower mold flanges 12 on both sides of the first cavity 11 in the width direction Y, and the upper mold 20 has upper mold flanges 22 on both sides of the second cavity 21 in the width direction Y. The upper mold flanges 22 and the lower mold flanges 12 are arranged opposite to each other and can have the same width. A sealing material can be provided between the two flanges. The sealing material extends in the direction corresponding to the flanges, that is, the sealing material can be provided to extend along the length direction X to enhance the airtightness of the hollow cavity 30.

[0077] Understandably, the upper mold flange 22 and the lower mold flange 12 can be simultaneously provided on both sides of the hollow cavity 30 in the length direction X and both sides in the width direction Y, that is, flanges are provided around the hollow cavity 30, thereby making the connection between the upper mold 20 and the lower mold 10 more stable. At this time, sealing material can also be correspondingly provided around the hollow cavity 30 to form a closed ring around the hollow cavity 30, further improving the airtightness of the hollow cavity 30.

[0078] In some alternative embodiments, the first cavity 11 and the second cavity 21 have opposite recess directions and the same recess depth.

[0079] As mentioned above, the first cavity 11 of the lower mold 10 and the second cavity 21 of the upper mold 20 are arranged opposite to each other and together form a hollow cavity 30. As an example, the first cavity 11 and the second cavity 21 can have the same depth, and the upper mold 20 and the lower mold 10 can also have the same thickness. This allows the upper mold 20 and the lower mold 10 to be arranged approximately symmetrically about the parting surface, which facilitates the processing of the mold and the demolding of the double webs, and also facilitates the cleaning and reinforcement of the double webs.

[0080] In some alternative embodiments, the height of the core mold 40 in the recess direction of the first cavity 11 is greater than the recess depth of the first cavity 11.

[0081] Corresponding to the parting surface being located in the middle in the thickness direction Z, the height of the core mold 40 in the thickness direction Z should be greater than the depth of the first cavity 11, so that when the core mold 40 is placed in the first cavity 11, it is at least partially exposed outside the first cavity 11, thereby making it easier to demold the formed double web plate.

[0082] In some alternative embodiments, the mold 100 further includes a heating system disposed on the lower mold 10 and the upper mold 20, the heating system being capable of heating the hollow cavity 30.

[0083] After the hollow cavity 30 is filled, the filling material needs to be heated to solidify and form. Therefore, the mold 100 in this embodiment can also integrate a heating system, which is simultaneously located in the lower mold 10 and the upper mold 20 to ensure uniform and stable heating. The heating system can heat the internal hollow cavity 30 through the mold, causing the filling material to heat up and solidify, ultimately forming the required double web. It is understood that the heating system can be integrated into the upper mold 20 and the lower mold 10, meaning the heating system can be evenly distributed inside the mold 100, positioned close to the sidewall of the hollow cavity 30. This allows the heating system to be closer to the filling material while ensuring molding quality, thereby improving heating efficiency.

[0084] Please refer to the following: Figures 4 to 7 , Figure 4 This is a flowchart of the molding method provided in the embodiments of this application. Figure 5 yes Figure 4 The schematic diagram of the structure corresponding to step S2 of the molding method shown is as follows: Figure 6 yes Figure 4 The schematic diagram of the structure corresponding to step S4 of the molding method shown is as follows. Figure 7 yes Figure 4 A schematic diagram of the structure corresponding to step S5 of the molding method shown. Secondly, according to an embodiment of this application, a molding method is proposed for molding a double-web structure, the molding method comprising:

[0085] S1. Provide a mold 100 as described in any embodiment of the first aspect;

[0086] S2. Lay up a layer structure 50 in the lower mold 10. The layer structure 50 includes a first layer 51, a second layer 52, and a first core material 53 sandwiched between the first layer 51 and the second layer 52. The first core material 53 is disposed in the first cavity 11 and together with the portions of the first layer 51 and the second layer 52 located in the first cavity 11, it forms a main body 54. The first layer 51 and the second layer 52 both extend at least partially outside the first cavity 11, and the portions extending outside the first cavity 11 together form an extension 55.

[0087] S3. Place the core mold 40 in the first cavity 11 and stack it with the main body 54;

[0088] S4. Fold the extension 55 back and place the second core material 56 between the first ply 51 and the second ply 52 in the part covering the core mold 40. The extension 55 overlaps with the main body 54 to form a closed loop.

[0089] S5. Snap the upper mold 20 and the lower mold 10 together inside to form a whole to be poured;

[0090] S6. Vacuum the entire area to be filled, pour in the resin, and cure it.

[0091] S7. Separate the lower mold 10 and the upper mold 20 to extract the elastomer 41 to form a double web.

[0092] Optionally, this application embodiment also provides a processing method for forming a double web using the mold 100 in the aforementioned embodiment. When using this forming method, a mold 100 is first provided, and a layup structure 50 is provided in the first cavity 11 of the lower mold 10. The layup structure 50 includes a first layup 51, a first core material 53, and a second layup 52 stacked sequentially. In addition to the portion of the first layup 51 and the second layup 52 that is laid in the first cavity 11 to form the main body 54, they also have an extension 55 that extends laterally along the width direction Y. The length of the extension 55 in the width direction Y should be greater than the sum of the length of the hollow cavity 30 in the width direction Y and the length of the hollow cavity 30 in the thickness direction Z, so as to ensure that the extension 55 can overlap with the starting end of the main body 54 after being folded back and form a circumferentially closed annular layup. It is understandable that the first ply 51 is used to form the outer surface of the double web structure. Therefore, the length of the first ply 51 in the width direction Y can be greater than the length of the second ply 52 in the width direction Y, so as to ensure that both can form a closed loop structure.

[0093] The first core material 53 in the layup structure 50 is disposed in the first cavity 11 and sandwiched between the first layup 51 and the second layup 52. The first core material 53 is the substrate used to form one of the webs of the double-web structure 200. The first core material 53 can be PVC (Polyvinyl chloride) foam or PET (Polyethylene terephthalate) foam, or similar lightweight materials with a certain strength. The first core materials 53 are stacked sequentially along the length X of the first cavity 11, and the stacking width and thickness of the first core materials 53 can be adjusted accordingly based on the required width and thickness of the web to be formed. Optionally, the first layup 51 and the second layup 52 can be fiberglass cloth. Fiberglass cloth is lightweight, has good covering function and tensile strength. This application does not impose specific limitations on the specific type of fiberglass cloth, and adjustments can be made according to the needs of use and processing.

[0094] After the ply structure 50 is set up, the core mold 40 can be stacked on the main body 54. The distance between the orthographic projection of the core mold 40 on the main body 54 in the width direction Y and the two side edges of the main body 54 is the thickness of the two connecting parts located between the front web and the rear web. The core mold 40 can be adjusted accordingly according to the design value of the thickness.

[0095] Subsequently, the aforementioned extension 55 is folded back, and a second core material 56 is placed between the first ply 51 and the second ply 52. ​​The second core material 56 is the base material for the other web in the double-web structure 200 to be formed. Similar to the first core material 53, the stacking width and thickness of the second core material 56 are designed according to the required shape parameters of the web to be formed. The material of the second core material 56 can be the same as that of the first core material 53. It is understood that the orthographic projection of the second core material 56 on the core mold 40 is within the outline of the core mold 40, that is, the second core material 56 is stacked on the core mold 40. Therefore, there are certain requirements for the material strength of the elastomer 41 in the core mold 40. The elastomer 41 needs to ensure that it will not undergo significant deformation due to weight after the second core material 56 is set.

[0096] In this embodiment, after the extension 55 is folded back and covers the core mold 40, its edge in the width direction Y should be able to overlap with the edge of the main body 54. That is, the overall width of the first layup 51 needs to be greater than the perimeter of the cross section of the hollow cavity 30 in the plane perpendicular to the length direction X, and the overall width of the second layup 52 needs to be greater than the perimeter of the cross section of the core mold 40 in the plane perpendicular to the length direction X, so as to ensure that the two ends of the layup structure 50 can overlap each other and form a closed ring after it is wrapped around once, so as to form a ring-shaped double web structure.

[0097] It is understood that adhesive bonding can be used to assist in fixing the first ply 51 and the second ply 52 at their overlap, thereby further improving the reliability of the structure. Meanwhile, the first ply 51 and the second ply 52 can be formed from a single layer of ply material or from multiple layers of ply material spliced ​​together. In embodiments where the first ply 51 and the second ply 52 are spliced ​​together, the splicing points of the ply materials should at least partially overlap to ensure the integrity of the structure after grouting.

[0098] After the layup structure 50 is set up, the upper mold 20 can be aligned and fastened, docking with the lower mold 10 to form the entire assembly to be poured, including the layup structure 50. The upper mold 20 and lower mold 10 can be connected and fixed by a flange, or other detachable connection methods can be used. After the lower mold 10 and upper mold 20 are fastened together, their internal cavity needs to have a certain degree of airtightness to avoid air leakage during subsequent vacuuming of the entire assembly to be poured.

[0099] Once the entire assembly to be infused is formed, it can be evacuated. At this time, the vacuum bag assembly 42 in the core mold 40 is connected to the outside through the interface, so that the interior maintains a normal pressure environment. During the evacuation process of the entire assembly to be infused, a pressure difference is gradually formed between the inside and outside of the vacuum bag assembly 42, causing at least the outermost vacuum bag assembly 42 to expand outward, and stably press the layered structure 50 onto the cavity wall of the hollow cavity 30 to form the shape of the double web to be formed. Then, infusion and heating curing can be performed.

[0100] Understandably, when using the mold 100 for vacuuming, the vacuum system for evacuating the hollow cavity 30 can have an overflow function. That is, one end of the evacuation pipe connected to the hollow cavity 30 is first connected to an overflow tank, and then the overflow tank is connected to a vacuum pump. This allows for observation of whether the injection material has been extracted from the evacuation pipe, thus determining the wetting status of the injection material inside the mold 100 and accurately controlling the injection process. Optionally, the injection material is typically resin.

[0101] After the injection material inside the mold has solidified, the upper and lower molds can be separated. First, the upper mold 20 is lifted to expose the internal double-web structure, and then the double-web structure is demolded from the lower mold 10. The formed double-web structure is an integrally formed annular double web, which is not closed at the blade root end and the blade tip end. Therefore, the core mold 40 can be pulled out through the opening located in the blade root direction to complete the demolding of the double-web structure. After subsequent cleaning, polishing and other processes, a complete and usable double-web structure 200 can be obtained.

[0102] The molding method provided in this application embodiment can mold the front and rear web plates in one step, saving the time, tooling, and site costs required to assemble the two web plates, and can effectively improve production efficiency and reduce production costs.

[0103] Please see Figure 8 , Figure 8 This is a partial flowchart of the molding method provided in the embodiments of this application. In some optional embodiments, the step of laying the layer structure 50 in the lower mold 10 includes:

[0104] S2.1 A first layup 51 is laid on the lower mold 10. The first layup 51 includes a first region 511 covering the first cavity 11 and a second region 512 extending out of the first cavity 11.

[0105] S2.2 Lay the first core material 53 in the first zone 511;

[0106] S2.3. A second layup 52 is laid on the first core material 53 and the second region 512. The second layup 52 includes a third region 521 covering the first core material 53 and a fourth region 522 covering the second region 512.

[0107] In the step of setting the layup structure 50 on the lower mold 10, a first layup 51 is first laid on the lower mold 10. One end of the first layup 51 in the width direction Y can be flush with the opening edge of the first cavity 11 or slightly extra to facilitate overlapping in subsequent processes. The other end of the first layup 51 in the width direction Y extends outward to form an extension 55. The first layup 51 includes a first region 511 covering the first cavity 11 and a second region 512 extending outward. The first region 511 is used to form the main body 54, and the second region 512 is used to form the extension 55.

[0108] After the first ply 51 is laid, the first core material 53 can be laid on the first area 511, that is, on the part of the first ply 51 located in the first cavity 11. The first core material 53 extends in the same direction as the first cavity 11.

[0109] Subsequently, a second ply 52 is laid on the first core material 53. The second ply 52 is laid on the first core material 53 and the first ply 51. Similar to the first ply 51, the second ply 52 includes a third region 521 covering the first core material 53 and a fourth region 522 covering the aforementioned second region 512. The third region 521, together with the first core material 53 and the first region 511, forms the main body 54 disposed in the first cavity 11. The fourth region 522 extends in the same direction as the second region 512 and together forms the extension 55. The second region 512 and the fourth region 522 can have the same length in the width direction Y, or the fourth region 522 can be slightly shorter.

[0110] Please see Figure 9 , Figure 9 This is a partial flowchart of the molding method provided in the embodiments of this application. In some optional embodiments, the step of folding back the extension 55 and placing the second core material 56 between the first layup 51 and the second layup 52 covering the core mold 40 includes:

[0111] S4.1 Fold back the fourth zone 522 of the second layer 52 so that the fourth zone 522 covers the core mold 40;

[0112] S4.2 Lay the second core material 56 on the side of the fourth zone 522 of the second ply 52 away from the core mold 40;

[0113] S4.3 Fold back the second zone 512 of the first layup 51 so that the second zone 512 covers the second core material 56.

[0114] Corresponding to step S2 of laying the ply structure 50 in the lower mold 10, the step of folding the ply structure 50 back and covering the core mold 40 can include three sub-steps. First, the fourth region 522 of the second ply 52 located on the inner side is folded back so that it covers the core mold 40, and the edge of the fourth region 522 overlaps with the edge of the first region 511, so that the second ply 52 forms a closed annular layer structure surrounding the core mold 40, so as to form the inner surface of the annular double web structure after injection molding.

[0115] Subsequently, the second core material 56 is laid in the area above the core mold 40 of the second ply 52. ​​At this time, the weight of the second core material 56 is supported by the elastic body 41 in the core mold 40. The second core material 56 also extends in the same direction as the first cavity 11.

[0116] After the second core material 56 is laid, the second region 512 of the first ply 51 can be folded back to cover the second core material 56, and the edge of the second region 512 can be overlapped with the edge of the first region 511, so that the first ply 51 forms an annular layer structure that encloses the core mold 40, the first core material 53, the second core material 56 and the second ply 52, so as to form the outer surface of the annular double web structure after injection molding.

[0117] In some alternative embodiments, prior to the step of separating the lower mold 10 and the upper mold 20 and extracting the elastomer 41 to form the double web, the forming method further includes:

[0118] The inside of the vacuum bag assembly is drawn in to reduce the volume of the elastomer.

[0119] The core mold 40 in this embodiment includes an elastomer 41 and a vacuum bag assembly 42 enclosing the elastomer 41. Before removing the core mold 40 from between the formed double webs, a vacuum can be drawn inside the innermost vacuum bag 421. At this time, the space between the inner and outer vacuum bags 421 is a normal pressure environment formed by the interface, thereby creating a pressure difference between the inside and outside of the inner vacuum bag 421. This causes the inner vacuum bag 421 to contract inward and compress the elastomer 41, thereby reducing the volume of the elastomer 41, creating a gap between it and the formed double webs, and making it easier to detach, thus making the demolding of the double webs smoother. When removing the elastomer 41, a forklift or other equipment can be used to assist in pulling the elastomer 41 out as a whole.

[0120] In some optional embodiments, prior to the step of placing the core mold 40 in the first cavity 11 and stacking it with the main body 54, the molding method further includes:

[0121] A flow guide net and flow channel are provided between the core mold 40 and the second layup 52 located in the main body 54.

[0122] The molding method provided in this application embodiment processes the web through injection and curing. Therefore, before injection, corresponding injection auxiliary devices, such as flow guides and flow channels, are required. In this application embodiment, the flow guide and flow channels can be located below the core mold 40 and above the main body 54, that is, sandwiched between the vacuum bag assembly 42 and the second layup 52. Positioning the flow guide and flow channels below the core mold 40 allows the injection material to fully impregnate the first core material 53 and the first region 511 and the third region 521.

[0123] Correspondingly, the molding method provided in this application embodiment may further include, before step S4: setting a flow guide net and a flow channel between the core mold 40 and the second layup 52 covering the core mold 40, that is, the flow guide net and flow channel can be set on both sides of the core mold 40 along the thickness direction Z, thereby improving the uniformity of pouring and wetting and improving the molding quality.

[0124] In some alternative embodiments, after separating the lower mold 10 and the upper mold 20 and extracting the elastomer 41 to form the double web, the forming method further includes:

[0125] Remove the vacuum bag assembly 42 that is attached to the inner surface of the double webs.

[0126] The mold 100 provided in this embodiment includes a vacuum bag assembly 42. During the vacuuming step before injection, the outermost vacuum bag 421 of the vacuum bag assembly 42 expands outward, pressing the layered structure 50 against the cavity wall of the hollow cavity 30. Therefore, after injection molding, the outermost vacuum bag 421 may be adhered to the inner wall of the annular double web by the injection material. Based on this, the molding method provided in this embodiment may further include cleaning and removing the vacuum bag assembly 42 that is attached to the inner surface of the double web to avoid the vacuum bag assembly 42 affecting the molded double web and ensuring that the double web has the required strength and quality.

[0127] It is understandable that auxiliary components such as flow guides and flow channels used in the injection molding of the web plate will remain inside the double web plate structure after molding and demolding. Therefore, they can be cleaned and removed at the same time as the vacuum bag assembly 42, in order to save time.

[0128] Please see Figure 10 , Figure 10 This is a schematic diagram of the double-web structure provided in the embodiments of this application. In a third aspect, according to an embodiment of this application, a double-web structure 200 is proposed, which is formed using the molding method in any embodiment of the second aspect. The double-web structure 200 includes: a front web 60, a first connecting portion 70, a rear web 80, and a second connecting portion 90. The front web 60, the first connecting portion 70, the rear web 80, and the second connecting portion 90 are sequentially connected end-to-end to form a closed loop and are integrally molded.

[0129] This application embodiment also provides an annular double-web structure 200, which is composed of a leading edge web 60, a first connecting portion 70, a trailing edge web 80, and a second connecting portion 90 connected end to end in sequence, and is integrally formed using the aforementioned double-web molding method. The double-web structure 200 provided in this application embodiment is a closed ring in the circumferential direction, thus preventing adhesive from squeezing out from the gaps between the webs when bonding with the blade skin. This eliminates the need for manual cleaning of excess adhesive inside the webs, effectively improving production efficiency. Furthermore, the double-web structure 200 provided in this application embodiment is integrally molded, eliminating the need for assembling the leading edge web 60 and the trailing edge web 80 and waiting for the adhesive used in assembly to cure, further improving production efficiency.

[0130] Please see Figure 11 , Figure 11 This is a schematic diagram of the blade structure provided in the embodiments of this application. In a fourth aspect, an embodiment of this application proposes a blade 300 for use in a wind turbine generator set, including the double-web structure 200 proposed in the third aspect.

[0131] Please see Figure 12 , Figure 12 This is a schematic diagram of the structure of a wind turbine generator set provided in an embodiment of this application. In a fifth aspect, an embodiment of this application provides a wind turbine generator set 400, including at least one blade 300 as described in the fourth aspect.

[0132] This application embodiment also provides a blade 300 and a wind turbine generator set 400, wherein the blade 300 includes the aforementioned integrally formed annular double web structure 200, and the wind turbine generator set 400 includes at least one blade 300. Thus, the blade 300 and the wind turbine generator set 400 provided in this application embodiment have all the beneficial effects of the aforementioned double web structure 200. For details, please refer to the specific descriptions of the double web structure 200 and the forming method in the above embodiments, which will not be repeated here.

[0133] Although this application has been described with reference to preferred embodiments, various modifications can be made thereto and components can be replaced with equivalents without departing from the scope of this application. In particular, the technical features mentioned in the various embodiments can be combined in any manner, provided there is no structural conflict. This application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A mold (100) for forming a double web of a blade, characterized in that, The mold (100) includes: The lower mold (10) has a first cavity (11); The upper mold (20) can be engaged with the lower mold (10) to form a closed hollow cavity (30). A core mold (40) can be disposed in the hollow cavity (30). The core mold (40) includes an elastomer (41) and a vacuum bag assembly (42). The elastomer (41) is filled in the vacuum bag assembly (42). The volume of the elastomer (41) can shrink or expand with the change of air pressure in the vacuum bag assembly (42). The vacuum bag assembly has an openable and closable interface. The vacuum bag assembly (42) includes two or more vacuum bag bodies (421), the two or more vacuum bag bodies (421) are stacked and at least the outermost vacuum bag body (421) has the interface; The vacuum bag assembly (42) can switch between a first state and a second state. In the first state, the vacuum bag assembly (42) is in contact with the elastomer (41). In the second state, there is a gap between the outermost vacuum bag body (421) and the elastomer (41).

2. The mold (100) according to claim 1, characterized in that, The elastomer (41) includes at least one of sponge, foam, and rubber.

3. The mold (100) according to claim 1, characterized in that, The elastomer (41) includes a plurality of sub-elastomers, which are connected in series.

4. The mold (100) according to claim 1, characterized in that, The distance between the orthographic projection of the core mold (40) at the bottom of the first cavity (11) and the distance between the two side walls of the first cavity (11) extending along its own length direction (X) is equal.

5. The mold (100) according to any one of claims 1 to 4, characterized in that, The lower mold (10) further includes a lower mold flange (12), and the first cavity (11) is provided with the lower mold flange (12) on both sides of its own width direction (Y). The upper mold (20) includes a second cavity (21) and an upper mold flange (22), and the second cavity (21) is provided with the upper mold flange (22) on both sides of its width direction (Y). The upper mold flange (22) and the lower mold flange (12) can be sealed together, and the first cavity (11) and the second cavity (21) are connected to form the hollow cavity (30).

6. The mold (100) according to claim 5, characterized in that, The first cavity (11) and the second cavity (21) have opposite recess directions and the same recess depth.

7. The mold (100) according to claim 5, characterized in that, The height of the core mold (40) in the recessed direction of the first cavity (11) is greater than the recessed depth of the first cavity (11).

8. The mold (100) according to claim 1, characterized in that, The mold (100) also includes a heating system disposed on the lower mold and the upper mold, the heating system being capable of heating the hollow cavity (30).

9. A molding method for molding a double-web structure, characterized in that, include: A mold (100) as described in any one of claims 1 to 8 is provided; A layup structure (50) is laid in the lower mold (10). The layup structure (50) includes a first layup (51), a second layup (52), and a first core material (53) sandwiched between the first layup (51) and the second layup (52). The first core material (53) is disposed in the first cavity (11) and together with the portions of the first layup (51) and the second layup (52) located in the first cavity (11) form a main body (54). The first layup (51) and the second layup (52) both extend at least partially outside the first cavity (11), and the portions extending outside the first cavity (11) together form an extension (55). The core mold (40) is placed in the first cavity (11) and stacked with the main body (54); The extension (55) is folded back and a second core material (56) is provided between the first layup (51) and the second layup (52) covering the core mold (40). The extension (55) overlaps with the main body (54) to form a closed loop. The upper mold (20) and the lower mold (10) are fastened together inside to form a whole to be poured; The entire assembly to be injected is evacuated, resin is injected, and then cured and molded. Separate the lower mold (10) and the upper mold (20) and extract the elastomer (41) to form a double web.

10. The molding method according to claim 9, characterized in that, The step of laying the layer structure (50) in the lower mold (10) includes: The first layup (51) is laid on the lower mold (10). The first layup (51) includes a first area (511) covering the first cavity (11) and a second area (512) extending out of the first cavity (11). The first core material (53) is laid in the first area (511); A second layup (52) is laid on the first core material (53) and the second region (512), the second layup (52) including a third region (521) covering the first core material (53) and a fourth region (522) covering the second region (512).

11. The molding method according to claim 10, characterized in that, The step of folding back the extension (55) and placing the second core material (56) between the first layup (51) and the second layup (52) covering the core mold (40) includes: Fold back the fourth region (522) of the second layup (52) so that the fourth region (522) covers the core mold (40). The second core material (56) is laid on the side of the fourth region (522) of the second layup (52) away from the core mold (40). Fold back the second region (512) of the first layup (51) so that the second region (512) covers the second core material (56).

12. The molding method according to claim 9, characterized in that, Prior to the steps of separating the lower mold (10) and the upper mold (20) and extracting the elastomer (41) to form the double web, the forming method further includes: The vacuum bag assembly (42) is evacuated to reduce the volume of the elastomer (41).

13. The molding method according to claim 9, characterized in that, Before the step of placing the core mold (40) in the first cavity (11) and stacking it with the main body (54), the molding method further includes: A flow guide and flow channel are provided between the core mold (40) and a portion of the second layup (52) located in the main body (54).

14. The molding method according to claim 9, characterized in that, After the steps of separating the lower mold (10) and the upper mold (20) and extracting the elastomer (41) to form the double web, the forming method further includes: Remove the vacuum bag assembly (42) that is attached to the inner surface of the double webs.

15. A double-web structure (200), formed by the molding method as described in any one of claims 9-14, characterized in that, The double web structure (200) includes: a front web (60), a first connecting part (70), a rear web (80), and a second connecting part (90). The front web (60), the first connecting part (70), the rear web (80), and the second connecting part (90) are connected end to end in sequence to form a closed ring and are integrally formed.

16. A blade (300) used in a wind turbine generator set, characterized in that, Includes the double web structure (200) as described in claim 15.

17. A wind turbine generator set (400), characterized in that, Includes at least one blade (300) as described in claim 16.

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