Infusion system for large components and construction method thereof

Abstract

The present invention relates to the technical field of composite materials, and in particular to a perfusion system for large components and a construction method thereof; the system comprises a mold, a perfusion assembly and a vacuum assembly, the mold being a female mold, and a mold cavity being opened in the mold, and a rib one and a rib two being respectively arranged on both sides of the mold, and a mold exhaust port being arranged on the mold and being located on the outside of the rib one; the present invention adopts a combination of upper and lower perfusion, and a flow guide medium is laid on the upper and lower sides of a reinforcing material, while improving the auxiliary material arrangement scheme and increasing the width, so that the provided perfusion system for large components has better performance; the present invention can effectively avoid a number of perfusion defects that are easily caused by the excessive width of large components during production, and improve the perfusion quality without affecting production efficiency.

Description

Technical Field

[0001] The invention relates to the technical field of composite materials, in particular to a perfusion system for large components and a construction method thereof. Background Art

[0002] At present, in the field of composite materials, the vacuum infusion molding process is mostly used to produce prefabricated parts, and the corresponding guide systems are designed for wind turbine blade beams with a width of about 600 mm, and most of them use single-sided infusion. When such guide systems are used for the infusion of large components, the following problems are prone to occur: (1) The reinforcement material of large components is a unidirectional fiber cloth that is stacked layer by layer, which is tight and has a large width. The auxiliary material arrangement scheme of the existing guide system cannot meet its exhaust requirements. The exhaust efficiency is low and there is residual air in the gaps between the fabrics. After infusion molding, it is easy to cause large-area air threads, whitening and other defects. (2) The unidirectional fiber cloth itself has poor wettability. At the same time, the width is twice the conventional width. The resin infiltration speed is slow if it is only injected on one side, and it is difficult to complete sufficient impregnation before the resin gels, which ultimately leads to a serious lack of glue content in the product and even the appearance of dry fibers.

[0003] In addition, some existing unconventional wind turbine blade beam infusion structures or technical solutions cannot effectively solve the above problems. For example, the design described in patent announcement number CN211334655U adopts intermediate injection to increase the injection speed, but considering that the internal negative pressure is large during injection and the guide groove is under great downward pressure, arranging the guide groove directly above the reinforcement material is prone to wrinkles or resin compression and whitening. At the same time, the guide medium under the reinforcement material in this design does not overlap the guide groove, which cannot play a role in diffusing the resin in the early stage of infusion. Although the resin front reaches both sides, it helps to diffuse, but it also increases the risk of flow. Another design described in patent announcement number CN110884167B achieves synchronous infiltration of the reinforcement material up and down by laying upper and lower guide media, but it adds a spiral tube in the guide groove to limit the spanwise flow of the resin, which is not conducive to shortening the overall injection time. At the same time, in order to prevent the flow, the exhaust area is small and cannot meet the exhaust requirements of large components.

[0004] Therefore, the present invention provides a large-scale component perfusion system and a construction method thereof, which are used to solve the above-mentioned related technical problems. Summary of the invention

[0005] The purpose of the present invention is to provide a large-scale component casting system and a construction method thereof, which can effectively avoid multiple casting defects easily caused by the excessive size of large-scale components during production, and improve the casting quality without affecting the production efficiency.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] The first aspect of the present invention provides a perfusion system for large components, including a mold, a perfusion assembly and a vacuum assembly, wherein the mold is a female mold, and a mold cavity is opened in the mold, and cross-sectional sidewalls 1 and 2 are respectively provided on both sides of the mold, and a mold exhaust port is provided on the mold, which is located on the outside of sidewall 1.

[0008] The present invention is further configured as follows: the perfusion component is installed in the inner cavity of the mold, the perfusion component includes a lower surface guide net, a lower surface perforated film, a lower surface release cloth, an upper surface release cloth, an upper surface perforated film and an upper surface guide net, which are arranged in sequence from bottom to top, the perfusion component also includes a PP profile guide groove and a perfusion glue injection port, the PP profile guide groove is installed at a distance of 10 to 50 mm from the second outer corner of the retaining edge, and the perfusion glue injection port is installed at the connection and disconnection point of the two PP profile guide grooves.

[0009] The present invention is further configured as follows: the vacuum component includes an upper surface suction adhesive, a VAP vacuum bag, a spiral tube, a first layer of vacuum film, an air-conducting suction adhesive, a second layer of vacuum film and a sealing strip; the upper surface suction adhesive is arranged on the upper surface guide net, the VAP vacuum bag is arranged on the upper surface suction adhesive, the mold is connected to the first layer of vacuum film, the air-conducting suction adhesive and the second layer of vacuum film through a sealing strip, and the spiral tube is arranged on the vacuum side of the mold.

[0010] The present invention is further configured as follows: a reinforcing material is provided on the lower surface release cloth, and the overlapping width between the reinforcing material and the upper surface guide net is 400 to 500 mm.

[0011] The present invention is further configured as follows: the lower surface guide net is a woven guide net, which is easy to bend and can better fit the inner corner of the side guard of the mold casting side to avoid wrinkles.

[0012] The present invention is further configured as follows: the upper surface guide net is an extruded guide net, which has a better guide effect and helps to accelerate the uniform diffusion of the resin.

[0013] The present invention is further configured as follows: the width of the VAP vacuum bag is at least 250 mm, and the width of the VAP vacuum bag does not exceed one third of the width of the mold. The width of the VAP vacuum bag should be selected to ensure sufficient vacuum coverage area to improve the vacuum efficiency, but should not be too wide to result in insufficient width of the guide net arranged on the upper surface of the component, thereby affecting the resin diffusion rate.

[0014] The present invention is further configured as follows: the bottom surface of the VAP vacuum bag is a VAP film that is breathable and resin-impermeable, the top surface is a transparent vacuum film through which the internal conditions can be observed, the middle is an extruded guide net, and the vacuum side of the VAP vacuum bag is provided with a transverse fork to connect to the mold vacuum port, which can be directly connected to the vacuum port and ensure sealing.

[0015] The present invention is further configured as follows: the width of the upper surface adhesive is at least 300 mm, and the width of the upper surface adhesive does not exceed one third of the width of the mold. The width of the upper surface adhesive should be selected to ensure sufficient air guide coverage area and minimize the air residue in the fiber gap of the component, but it should not be too wide to cause insufficient width of the guide net arranged on the upper surface of the component, thereby affecting the resin diffusion rate.

[0016] The second aspect of the present invention also provides a method for constructing the above-mentioned large-scale component perfusion system, comprising the following steps:

[0017] Step 1: Prepare the mold and paste the sealing strip;

[0018] Step 2: Lay the lower surface guide net in the mold cavity along the length direction and adjust the lateral position;

[0019] Step 3: Lay the lower surface perforated film and the lower surface demoulding cloth in the mold cavity in sequence along the length direction, and arrange the left and right edges to turn over the first and second retaining edges;

[0020] Step 4: Laying reinforcement materials;

[0021] Step 5: Lay the upper surface release cloth, the upper surface perforated film and the upper surface guide net in the mold cavity in sequence along the length direction, and adjust the lateral position;

[0022] Step 6: Lay the upper surface adhesive and VAP vacuum bag in sequence and adjust the horizontal position;

[0023] Step 7: Connect the VAP vacuum bag to the vacuum port, place the PP profile guide groove along the length of the mold on the injection side and install the injection port;

[0024] Step 8: Seal the first layer of vacuum film, then place the spiral tube along the length of the mold on the vacuum side, use air-guiding suction glue to lay it back and forth horizontally and overlap the spiral tube, and then seal the second layer of vacuum film;

[0025] Step 9: After preparation, evacuate and perform sealing inspection.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] The present invention adopts a combination of upper and lower perfusion, laying flow-guiding media on the upper and lower surfaces of the reinforcing material, and improving the auxiliary material arrangement scheme and increasing the width, so that the provided large-scale component perfusion system has the following advantages: (1) During the vacuum stage, when the mold is in a negative pressure state, the flow-guiding media on the upper and lower surfaces of the reinforcing material ensure that there are large areas of gaps on both sides for gas flow. At the same time, with the assistance of a large-width vacuum bag and suction glue, the overall vacuum efficiency is greatly improved, and internal gas residue is avoided to the greatest extent; (2) Upper and lower perfusion accelerates the lateral diffusion of the resin, and can directly infiltrate the upper and lower layers of fiber cloth, which not only ensures that the fiber cloth is fully impregnated but also shortens the injection time. The present invention can effectively avoid multiple perfusion defects that are easily caused by the excessive width of large components during production, and improve the perfusion quality without affecting production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0029] Figure 1 It is a schematic diagram of the structure of the pouring system for large components of the present invention.

[0030] Legend: 1. Mould; 2. Flow guide net on lower surface; 3. Film with holes on lower surface; 4. Release cloth on lower surface; 5. Reinforcement material; 6. Flow guide groove for PP profile; 7. Glue injection port; 8. Release cloth on upper surface; 9. Film with holes on upper surface; 10. Flow guide net on upper surface; 11. Glue suction on upper surface; 12. VAP vacuum bag; 13. Mould vacuum port; 14. Spiral tube; 15. First layer of vacuum film; 16. Air-guiding glue suction; 17. Second layer of vacuum film; 18. Sealing strip. DETAILED DESCRIPTION

[0031] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention; it is obvious that the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments, and all other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making creative work are within the scope of protection of the present invention.

[0032] In the description of the present invention, it should be noted that the terms "upper", "lower", "inner", "outer", "top / bottom" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific position, be constructed and operated in a specific position, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0033] In the description of the present invention, it should be noted that, unless otherwise clearly stipulated and limited, the terms "installed", "provided with", "mounted / connected", "connected", etc. should be understood in a broad sense. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be the internal connection of two components; for ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0034] Example

[0035] like Figure 1 As shown, this embodiment provides a large-scale component infusion system, including a mold 1, a infusion component and a vacuum component;

[0036] The mold 1 is a female mold, and a mold cavity is formed in the mold 1. The two sides of the mold 1 are respectively provided with a cross-section rib 1 and a rib 2. The mold 1 is provided with a mold exhaust port 13, which is located outside the rib 1.

[0037] The perfusion assembly is installed in the inner cavity of the mold 1, and the perfusion assembly includes a lower surface guide net 2, a lower surface perforated film 3, a lower surface demoulding cloth 4, an upper surface demoulding cloth 8, an upper surface perforated film 9 and an upper surface guide net 10, which are arranged in sequence from bottom to top. The perfusion assembly also includes a PP profile guide groove 6 and a perfusion glue injection port 7. The PP profile guide groove 6 is installed at a distance of 10 to 50 mm from the outer corner of the right retaining edge, and the perfusion glue injection port 7 is installed at the connection and disconnection of two PP profile guide grooves 6;

[0038] The vacuum assembly includes an upper surface suction adhesive 11, a VAP vacuum bag 12, a spiral tube 14, a first layer of vacuum film 15, an air-guiding suction adhesive 16, a second layer of vacuum film 17 and a sealing strip 18. The upper surface suction adhesive 11 is arranged on the upper surface guide net 10, the VAP vacuum bag 12 is arranged on the upper surface suction adhesive 11, the mold 1 is connected to the first layer of vacuum film 15, the air-guiding suction adhesive 16 and the second layer of vacuum film 17 through the sealing strip 18, and the spiral tube 14 is arranged on the vacuum side of the mold 1.

[0039] Furthermore, a reinforcing material 5 is provided on the lower surface release cloth 4, and the overlapping width between the reinforcing material 5 and the upper surface guide net 10 is 400-500 mm.

[0040] Furthermore, the lower surface guide net 2 is a woven guide net.

[0041] Furthermore, the upper surface guide net 10 is an extruded guide net.

[0042] Furthermore, the width of the VAP vacuum bag 12 is at least 250 mm, and the width of the VAP vacuum bag 12 does not exceed one third of the width of the mold 1 .

[0043] Furthermore, the bottom surface of the VAP vacuum bag 12 is a VAP film that is breathable but not resin-permeable, the top surface is a transparent vacuum film through which the internal conditions can be observed, the middle is an extruded guide net, and the vacuum side of the VAP vacuum bag 12 is provided with a lateral fork to connect to the mold vacuum port 13.

[0044] Furthermore, the width of the upper surface adhesive 11 is at least 300 mm, and the width of the upper surface adhesive 11 does not exceed one third of the width of the mold 1 .

[0045] In this embodiment, it should be noted that the reinforcing material 5 is made of unidirectional fiber cloth, and the lateral sides of the lower surface perforated film 3 and the lower surface demoulding cloth 4 must be turned out of the mold 1 rib, exceeding the width of 50 to 100 mm to avoid sticking to the mold and affecting demoulding. The same requirements apply to the flange arrangement of the upper surface perforated film 9 and the lower surface demoulding cloth 4; the upper surface guide net 10 is made of extruded guide net, which overlaps with the reinforcing material 5 with a width of 400 to 500 mm, is aligned with the lower surface guide net 2 on the side close to the injection glue, and exceeds the outer corner of the right rib of the mold 1 by 100 to 150 mm to ensure that the PP profile guide groove 6 has sufficient placement space; the PP profile guide groove 6 is 10 to 50 mm away from the outer corner of the right rib of the mold to avoid being too close to affect the diffusion of the resin; the injection port 7 is installed at the connection and disconnection point of the two PP profile guide grooves 6, with a disconnection distance of 30 to 50 mm to avoid being too close to affect the entry of the resin.

[0046] In addition, the width of the VAP vacuum bag 12 is 400mm, the width of the upper surface suction adhesive 11 is 350mm, and the overlap width of the two is 10 to 20mm; at the same time, the VAP vacuum bag 12 must be connected to the vacuum port of the mold 1, and ensure that the VAP vacuum bag 12 has no gaps to prevent resin from entering and affecting the vacuum efficiency; the first layer of vacuum film 15 and the second layer of vacuum film 17 must have margins in the length and width directions to avoid excessive tension after tightening, affecting the positioning of auxiliary materials or bonding detachment to cause leakage; the spiral tube 14 and the air-guiding suction adhesive 16 are arranged between the first layer of vacuum film 15 and the second layer of vacuum film 17, and the spiral tube 14 is placed on the vacuum side of the mold 1 and must be completely overlapped with the second layer of vacuum vacuum port; the air-guiding suction adhesive 16 is laid back and forth in a "Z" shape horizontally to connect the two sides of the mold 1, and must overlap with the spiral tube 14.

[0047] In addition, this embodiment also provides a method for constructing the above-mentioned large-scale component perfusion system, comprising the following steps:

[0048] Step 1: prepare the mold 1 and paste the sealing strip 18;

[0049] Step 2: Lay the lower surface guide net 2 in the inner cavity of the mold 1 along the length direction and adjust the lateral position;

[0050] Step 3: Lay the lower surface perforated film 3 and the lower surface release cloth 4 in the inner cavity of the mold 1 in sequence along the length direction, and arrange the left and right edges to turn over the first and second retaining edges;

[0051] Step 4: Laying reinforcement material 5;

[0052] Step 5: Lay the upper surface release cloth 8, the upper surface perforated film 9 and the upper surface guide net 10 in the inner cavity of the mold 1 in sequence along the length direction, and adjust the lateral position;

[0053] Step 6: Lay the upper surface adhesive 11 and the VAP vacuum bag 12 in sequence, and adjust the lateral position;

[0054] Step 7: Connect the VAP vacuum bag 12 to the vacuum port, place the PP profile guide groove 6 along the length direction of the mold 1 on the injection side, and install the injection port 7;

[0055] Step 8: seal the first layer of vacuum film 15, then place the spiral tube 14 along the length direction of the mold 1 on the vacuum side, use the air-conducting suction adhesive 16 to lay it back and forth horizontally and overlap the spiral tube 14, and then seal the second layer of vacuum film 17;

[0056] Step 9: After preparation, evacuate and perform sealing inspection.

[0057] In this embodiment, it should be noted that after the construction of the infusion system for large components is completed, the vacuum pump connected to the exhaust port of the mold 1 is turned on to start vacuuming the flow guide system. After the internal vacuum pressure is less than -0.096MPa, all vacuum pump valves are closed and a pressure holding test is performed. If the pressure drop does not exceed 0.002MPa within 15 minutes of pressure holding, the pressure holding is qualified and resin infusion can be started.

[0058] In the description of this specification, the description with reference to the terms "one embodiment", "example", "specific example", etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0059] The preferred embodiments of the present invention disclosed above are only used to help illustrate the present invention. The preferred embodiments do not describe all the details in detail, nor do they limit the invention to the specific implementation methods described. Obviously, many modifications and changes can be made according to the content of this specification. This specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the present invention, so that those skilled in the art can understand and use the present invention well. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. A perfusion system for large components, characterized in that: The invention comprises a mold (1), a pouring assembly and a vacuum assembly, wherein the mold (1) is a female mold, and a mold cavity is provided in the mold (1), and two sides of the mold (1) are respectively provided with a first cross-sectional retaining edge and a second cross-sectional retaining edge, and the mold (1) is provided with a mold exhaust port (13) located outside the first cross-sectional retaining edge; The pouring assembly is installed in the inner cavity of the mold (1), and comprises a lower surface guide net (2), a lower surface perforated film (3), a lower surface demoulding cloth (4), an upper surface demoulding cloth (8), an upper surface perforated film (9) and an upper surface guide net (10) arranged in sequence from bottom to top. The pouring assembly also comprises a PP profile guide groove (6) and a pouring glue injection port (7). The PP profile guide groove (6) is installed at a distance of 10 to 50 mm from the second outer corner of the retaining edge, and the pouring glue injection port (7) is installed at the connection and disconnection point of the two PP profile guide grooves (6); The vacuum assembly comprises an upper surface suction adhesive (11), a VAP suction bag (12), a spiral tube (14), a first layer of vacuum film (15), an air-conducting suction adhesive (16), a second layer of vacuum film (17) and a sealing tape (18); the upper surface suction adhesive (11) is arranged on the upper surface flow guide net (10); the VAP suction bag (12) is arranged on the upper surface suction adhesive (11); the mold (1) is connected to the first layer of vacuum film (15), the air-conducting suction adhesive (16) and the second layer of vacuum film (17) via the sealing tape (18); and the spiral tube (14) is arranged on the suction side of the mold (1); The bottom surface of the VAP vacuum bag (12) is a VAP film that is air-permeable but resin-impermeable, the top surface is a transparent vacuum film through which the internal conditions can be observed, the middle is an extruded guide net, and the vacuum side of the VAP vacuum bag (12) is provided with a transverse fork to connect to the mold vacuum port (13).

2. The large-scale component perfusion system according to claim 1, characterized in that: The lower surface demoulding cloth (4) is provided with a reinforcing material (5), and the overlapping width between the reinforcing material (5) and the upper surface guide net (10) is 400 to 500 mm.

3. The large-scale component pouring system according to claim 1, characterized in that: The lower surface guide net (2) is a woven guide net.

4. The large-scale component pouring system according to claim 1, characterized in that: The upper surface flow guide net (10) is an extruded flow guide net.

5. The large-scale component pouring system according to claim 1, characterized in that: The width of the VAP vacuum bag (12) is at least 250 mm, and the width of the VAP vacuum bag (12) does not exceed one third of the width of the mold (1).

6. The large-scale component pouring system according to claim 1, characterized in that: The width of the upper surface adhesive (11) is at least 300 mm, and the width of the upper surface adhesive (11) is no more than one third of the width of the mold (1).

7. A method for constructing a large-scale component perfusion system, using the large-scale component perfusion system according to any one of claims 1 to 6, comprising the following steps: Step 1: preparing the mold (1) and pasting the sealing strip (18); Step 2: Lay the lower surface guide net (2) in the inner cavity of the mold (1) along the length direction and adjust the lateral position; Step 3: Lay the lower surface perforated film (3) and the lower surface demoulding cloth (4) in the inner cavity of the mold (1) in sequence along the length direction, and arrange the left and right edges to turn over the first and second retaining edges; Step 4: Laying reinforcement material (5); Step 5: Lay the upper surface demoulding cloth (8), the upper surface perforated film (9) and the upper surface guide net (10) in the inner cavity of the mold (1) in sequence along the length direction, and adjust the lateral position; Step 6: Lay the upper surface adhesive (11) and the VAP vacuum bag (12) in sequence, and adjust the lateral position; Step 7: Connect the VAP vacuum bag (12) to the vacuum port, place the PP profile guide groove (6) along the length direction of the mold (1) on the injection side, and install the injection port (7); Step 8, seal the first layer of vacuum film (15), then place the spiral tube (14) along the length direction of the mold (1) on the vacuum side, use the air-conducting suction adhesive (16) to lay it back and forth horizontally and overlap the spiral tube (14), and then seal the second layer of vacuum film (17); Step 9: After preparation, evacuate and perform sealing inspection.

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