Blade component and method for manufacturing the same, and blade and method for manufacturing the same

Abstract

The present application provides a blade component and a manufacturing method thereof, as well as a blade and a manufacturing method thereof. The blade component is used in the blade of a wind turbine generator set, wherein the blade component includes glass fiber and a material having a plurality of active hydroxyl groups on the surface filled in the gap of the glass fiber, and the material having a plurality of active hydroxyl groups on the surface is a cross-linked product of epoxy resin and polyols. The blade component of the present application, since the surface of the blade component has active hydroxyl groups, when the blade component is used to manufacture the blade of a wind turbine generator set, the active hydroxyl groups on the surface of the blade component can undergo a cross-linking reaction with the glue-filling resin used to manufacture the blade, thereby ensuring the bonding strength of the components inside the blade at the connection interface, avoiding the problem of failure of the blade root or the main beam, and thus ensuring the service life of the blade.

Description

Technical Field

[0001] The present application relates to the technical field of wind power generation equipment, and in particular to a blade component, a method for manufacturing the blade component, a blade, and a method for manufacturing the blade. Background Art

[0002] The inside of the blade is generally embedded with metal bolt sleeves, wedge strips (made of fiber and resin after curing), main beams (made of fiber and resin after curing) and core wedge strips (made of PVC or PET) and other components. When manufacturing the blade, usually a part of the above-mentioned multiple components (for example, wedge strips) is wrapped with corresponding fiber fabrics, and each component is arranged in a mold, and then glue is poured. The fiber fabric and the glue pouring resin will be cured to form a fiberglass layer, so that the various components are bonded to each other to make a blade.

[0003] Existing blades have the phenomenon of failure of the blade root or main beam due to the loose connection interface, which is more common at the connection interface between the wedge strip and the fiberglass layer, thus greatly affecting the service life of the blade. Summary of the invention

[0004] The main purpose of the present application is to provide a blade component and a manufacturing method thereof, as well as a blade and a manufacturing method thereof, so as to improve the connection reliability of adjacent components inside the blade at the connection interface, thereby ensuring the service life of the blade.

[0005] According to a first aspect of the present application, a blade component is provided for use in a blade of a wind turbine generator set, wherein the blade component comprises glass fiber and a material having a plurality of active hydroxyl groups on the surface filled in the gaps of the glass fiber, and the material having a plurality of active hydroxyl groups on the surface is a cross-linked product of an epoxy resin and a polyol.

[0006] According to the blade component provided in the embodiment of the present application, since the surface of the blade component has active hydroxyl groups, when such blade component is used to manufacture blades of a wind turbine generator set, the active hydroxyl groups on the surface of the blade component can undergo a cross-linking reaction with the glue-potting resin used to manufacture the blades, thereby ensuring the bonding strength of the components inside the manufactured blade at the connection interface, avoiding the problem of blade root or main beam failure, and further ensuring the service life of the blade.

[0007] In some embodiments, the blade member is a wedge-shaped strip, and the weight of the cross-linked product accounts for 20%-25% of the total weight of the wedge-shaped strip.

[0008] In these embodiments, if the weight proportion of the cross-linked product in the wedge-shaped strip is less than 20%, it means that the weight proportion of the glass fiber in the wedge-shaped strip is relatively large, and the wedge-shaped strip is prone to defects such as dry yarn and whitening. If the weight proportion of the cross-linked product in the wedge-shaped strip is greater than 25%, it means that the weight proportion of the glass fiber in the wedge-shaped strip is relatively small, and the wedge-shaped strip may not be able to meet the relevant strength and stiffness requirements, thereby affecting the load-bearing capacity and service life of the blade.

[0009] In other embodiments, the blade component is a blade main beam, and the weight of the cross-linked product accounts for 14%-20% of the total weight of the blade main beam.

[0010] In these embodiments, if the weight proportion of the cross-linked product in the blade main beam is less than 14%, it means that the weight proportion of the glass fiber in the blade main beam is relatively large, and the blade main beam is prone to defects such as dry yarn and whitening, and the fatigue performance is reduced. If the weight proportion of the cross-linked product in the blade main beam is greater than 20%, it means that the weight proportion of the glass fiber in the blade main beam is relatively small, and the blade main beam cannot meet the relevant strength and stiffness requirements, thereby affecting the bearing capacity and service life of the blade.

[0011] In an embodiment, the wedge-shaped strip has an arcuate surface, and the arcuate surface has a rough structure.

[0012] In these embodiments, by providing a rough structure on the arc surface of the wedge strip, the bonding strength between the wedge strip and the fiberglass layer in the blade at the connection interface can be improved, thereby ensuring the stable operation of the blade and avoiding the risk of blade root failure.

[0013] In an embodiment, the rough structure is formed by a release cloth.

[0014] In these embodiments, the release cloth can form a uniform surface roughness structure, thereby ensuring the bonding strength between the wedge strip and the fiberglass layer at the connection interface, and the release cloth can be torn off before the wedge strip is arranged on the blade mold, thereby ensuring that the rough surface is free from contamination and thus avoiding affecting the bonding strength.

[0015] In an embodiment, the surface of the blade member has a plurality of holes.

[0016] In these embodiments, the surface of the blade component has multiple holes. During the blade manufacturing process, the product of the reaction between the glue-filling resin and the cross-linking product will fill the multiple holes on the surface of the blade component. The blade component and the fiberglass layer are connected to each other in an interlocking manner, thereby making the connection strength between the blade component and the fiberglass layer stronger.

[0017] According to a second aspect of the present application, a method for manufacturing a blade component is provided, wherein the blade component is used in a blade of a wind turbine generator set, wherein the method for manufacturing a blade component comprises the following steps: mixing an epoxy resin, an anhydride curing agent and a polyol in a predetermined proportion to obtain a mixture; using the mixture to impregnate glass fibers; and sintering the impregnated glass fibers to obtain a blade component of a material having a plurality of active hydroxyl groups on the surface, wherein the material having a plurality of active hydroxyl groups on the surface is a cross-linked product of an epoxy resin and a polyol.

[0018] In an embodiment, the step of obtaining the mixture includes first mixing the polyols and the epoxy resin, and then adding the anhydride curing agent to the mixture of the polyols and the epoxy resin, so as to obtain the mixture.

[0019] In these embodiments, the polyols and epoxy resins are first mixed, and then the anhydride curing agent is added to the former mixture to form a mixed material, which can reduce the probability of the anhydride curing agent and the polyols reacting, avoid side reactions (for example, the anhydride curing agent and the polyols reacting), and thus avoid affecting the performance of the prepared blade component. In addition, limiting the order of adding materials can ensure the amount of cross-linked products formed in the blade component, providing a sufficient amount of active hydroxyl groups for the subsequent reaction with the potting resin.

[0020] In an embodiment, the sintering is performed by a step-wise heating method, which includes heating the impregnated glass fiber to an initial temperature and keeping the temperature for a preset time, and then heating it to a curing temperature, thereby obtaining a blade component having active hydroxyl groups on the surface.

[0021] In these embodiments, under the effect of temperature, the glass fiber can be better infiltrated, thereby ensuring the uniformity of the formed blade component. In addition, heating to the initial temperature and keeping the temperature for a preset time can timely discharge the gas or solvent in the mixture, and then heating to the curing temperature, thereby avoiding defects (such as bubbles, etc.) in the formed blade component, thereby ensuring the compactness of the prepared blade component and ensuring that the blade component has sufficient load-bearing capacity.

[0022] In an embodiment, the equivalent ratio of the epoxy resin to the polyol is 12:(0.9-1.1), the weight ratio of the epoxy resin to the anhydride curing agent is 100:(95-105), and the weight ratio of the epoxy resin to the glass fiber is 100:(14-25).

[0023] In an embodiment, the viscosity of the mixture is 500-1000 haPas. The mixture is within a suitable viscosity range, which can ensure effective impregnation of the glass fiber. If the viscosity of the mixture is less than 500 haPas, the viscosity of the mixture is too small, which means that the ratio of the epoxy resin and the curing agent forming the mixture is not within a suitable range, which will cause the epoxy resin content in the impregnated glass fiber to account for a relatively small proportion, thereby affecting the performance of the prepared blade component. If the viscosity of the mixture is greater than 1000 haPas, the viscosity of the mixture is too high, which may cause the glass fiber to be unable to be fully impregnated by the mixture, so that the cross-linked products on the glass fiber of the blade component cannot be evenly distributed, and quality defects such as dry yarn and whitening are prone to occur.

[0024] In an embodiment, the method for manufacturing a blade component further comprises: before sintering, arranging a release cloth on the surface of the impregnated glass fiber, so as to obtain a blade component with a rough surface structure by removing the release cloth after solidification.

[0025] In these embodiments, when manufacturing the blade component, a release cloth is arranged on the surface of the impregnated glass fiber, so that a blade component with a release cloth on the surface can be manufactured. The release cloth can be removed when manufacturing the blade. On the one hand, the exposed rough structure on the surface of the blade component will make the bonding strength of the components inside the manufactured blade higher. On the other hand, the rough structure on the surface of the blade component is not contaminated, which can ensure the bonding strength to a certain extent.

[0026] According to a third aspect of the present application, a blade is provided, wherein the blade includes the blade component provided by the above-mentioned embodiments or includes a blade component manufactured by the method for manufacturing a blade component provided by the above-mentioned embodiments, and the blade also includes a fiberglass layer connected to the outside of the blade component, the fiberglass layer is formed by curing a fiber layup and an injection molding resin, and a product formed on the contact surface between the fiberglass layer and the blade component is formed by the reaction of the injection molding resin and the cross-linking product.

[0027] According to the blade provided in the embodiment of the present application, the active hydroxyl groups on the surface of the blade component can be connected with the fiberglass layer on the contact surface through chemical reaction, and have extremely high connection strength, so that the multiple components inside the blade are seamlessly formed into one, which can avoid the problem of blade failure due to unreliable connection interface, thereby ensuring the service life of the manufactured blade.

[0028] In an embodiment, the potting resin includes a mixture of epoxy resin and an amine curing agent.

[0029] According to a fourth aspect of the present application, a method for manufacturing a blade is provided, wherein the method for manufacturing a blade comprises: wrapping a fiber ply on the outside of a blade component to obtain a ply structure; impregnating the ply structure with an injection molding resin; sintering the ply structure impregnated with the injection molding resin, and controlling parameters of the sintering process to obtain a blade having a fiberglass layer formed by curing the injection molding resin and the fiber ply, wherein the blade component is the blade component provided in the above-mentioned embodiments or is a blade component manufactured by the method for manufacturing a blade component provided in the above-mentioned embodiments, and a product of the reaction between the injection molding resin and a cross-linking product is formed on the contact surface between the fiberglass layer and the blade component.

[0030] In an embodiment, the potting resin includes a mixture of epoxy resin and an amine curing agent.

[0031] In these embodiments, the epoxy resin and the amine curing agent in the potting resin can react with the active hydroxyl groups on the surface of the blade component, thereby further improving the bonding strength of the connection interface.

[0032] In an embodiment, the surface of the blade component has a plurality of pores, and the product of the reaction between the potting resin and the cross-linking product is filled in the plurality of pores.

[0033] In these embodiments, the reaction product of the potting resin and the cross-linking product will fill multiple holes on the surface of the blade component, and the blade component and the fiberglass layer are connected to each other in an interlocking manner, thereby making the connection strength between the blade component and the fiberglass layer stronger. DETAILED DESCRIPTION

[0034] The following specific embodiments are provided to help the reader obtain a comprehensive understanding of the methods, devices and / or systems described herein. However, after understanding the disclosure of the present application, various changes, modifications and equivalents of the methods, devices and / or systems described herein will be clear. For example, the order of operations described herein is only an example and is not limited to those orders set forth herein, but can be changed as will be clear after understanding the disclosure of the present application, except for operations that must occur in a specific order. In addition, for greater clarity and simplicity, the description of features known in the art may be omitted.

[0035] The features described herein can be implemented in different forms and should not be construed as being limited to the examples described herein. Rather, the examples described herein have been provided to illustrate only some of the many possible ways to implement the methods, devices, and / or systems described herein, which will be clear after understanding the disclosure of the present application.

[0036] As used herein, the term "and / or" includes any one of the associated listed items and any combination of any two or more.

[0037] Although terms such as "first", "second", and "third" may be used herein to describe various members, components, regions, layers, or portions, these members, components, regions, layers, or portions should not be limited by these terms. Instead, these terms are only used to distinguish one member, component, region, layer, or portion from another member, component, region, layer, or portion. Therefore, without departing from the teachings of the examples described herein, the first member, first component, first region, first layer, or first portion referred to in the examples may also be referred to as the second member, second component, second region, second layer, or second portion.

[0038] In the specification, when an element such as a layer, a region or a substrate is described as being “on”, “connected to” or “coupled to” another element, the element may be directly “on”, “connected to” or “coupled to” another element, or one or more other elements may be present therebetween. Conversely, when an element is described as being “directly on”, “directly connected to” or “directly coupled to” another element, other elements may not be present therebetween.

[0039] The terms used herein are only used to describe various examples and are not intended to limit the disclosure. Unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. The terms "comprise", "include" and "have" indicate the presence of the described features, quantities, operations, components, elements and / or combinations thereof, but do not exclude the presence or addition of one or more other features, quantities, operations, components, elements and / or combinations thereof. The term "plurality" represents any number of two and more than two.

[0040] The limitations of directional terms such as "upper", "lower", "top" and "bottom" in this application are all based on the directional limitations when the product is in normal use and placed upright.

[0041] Unless otherwise defined, all terms used herein, including technical terms and scientific terms, have the same meaning as those generally understood by ordinary technicians in the field to which the present invention belongs after understanding the present invention. Unless explicitly defined as such herein, terms such as those defined in general dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant field and the present invention, and should not be interpreted in an idealized or overly formal way.

[0042] Furthermore, in the description of the examples, when it is considered that a detailed description of a well-known related construction or function will cause vague interpretation of the present invention, such a detailed description will be omitted.

[0043] According to a first aspect of the present application, a blade component is provided for use in a blade of a wind turbine generator set, wherein the blade component includes glass fiber and a material having a plurality of active hydroxyl groups on the surface filled in the gaps between the glass fibers, wherein the material having a plurality of active hydroxyl groups on the surface is a cross-linked product of an epoxy resin and a polyol.

[0044] According to the blade component provided in the embodiment of the present application, since the surface of the blade component has active hydroxyl groups, when such blade component is used to manufacture blades of a wind turbine generator set, the active hydroxyl groups on the surface of the blade component can undergo a cross-linking reaction with the glue-potting resin used to manufacture the blades, thereby ensuring the bonding strength of the components inside the manufactured blade at the connection interface, avoiding the problem of blade root or main beam failure, and further ensuring the service life of the blade.

[0045] According to the present application, the blade component can be a part of the blade. The content of each component of the blade component affects the strength and stiffness of the blade to a certain extent. In the field of wind power generation, the strength and stiffness of the blade can affect the load-bearing capacity of the blade, and thus affect the service life of the blade.

[0046] In some embodiments, the blade component is a wedge-shaped bar, which can also be called a UD (Uni-direction stick, UD for short) rod, which is generally used to be pre-buried in the root of the blade to form a blade. Wherein, in the case where the blade component is a wedge-shaped bar, based on the total weight of the wedge-shaped bar, the weight of the cross-linked product accounts for 20%-25% of the total weight of the wedge-shaped bar, and the remainder is glass fiber. If the weight proportion of the cross-linked product in the wedge-shaped bar is less than 20%, it means that the weight proportion of the glass fiber in the wedge-shaped bar is relatively large, and the wedge-shaped bar is prone to defects such as dry yarn and whitening. If the weight proportion of the cross-linked product in the wedge-shaped bar is greater than 25%, it means that the weight proportion of the glass fiber in the wedge-shaped bar is relatively small, and the wedge-shaped bar may not be able to meet the relevant strength and stiffness requirements, thereby affecting the load-bearing capacity and service life of the blade.

[0047] In other embodiments, the blade component is a blade main beam. Wherein, in the case where the blade component is a blade main beam, based on the total weight of the blade main beam, the weight of the cross-linked product accounts for 14%-20% of the total weight of the blade main beam, and the remainder is glass fiber. If the weight proportion of the cross-linked product in the blade main beam is less than 14%, it means that the weight proportion of the glass fiber in the blade main beam is relatively large, and the blade main beam is prone to defects such as dry yarn and whitening, and the fatigue performance is reduced. If the weight proportion of the cross-linked product in the blade main beam is greater than 20%, it means that the weight proportion of the glass fiber in the blade main beam is relatively small, and the blade main beam cannot meet the relevant strength and stiffness requirements, thereby affecting the bearing capacity and service life of the blade.

[0048] During the operation and maintenance process, the inventors found that the root and main beam of the blade are prone to failure due to the unreliable connection interface, especially at the connection interface between the wedge strip and the fiberglass layer. This is due to the special-shaped structure of the wedge strip. Because the connection strength of the special-shaped structure at the connection interface is difficult to maintain uniformity, it is easy to cause peeling of the connection interface. In order to further improve the connection strength of the connection interface, according to the present application, for special-shaped blade components, a rough structure is set in the special-shaped area of ​​the blade component. In an exemplary embodiment, the blade component is a wedge strip, which can also be called a UD rod. The wedge strip has an arc surface, and the arc surface has a rough structure. By providing a rough structure on the arc surface of the wedge strip, the bonding strength between the wedge strip and the fiberglass layer in the blade at the connection interface can be further improved, thereby ensuring the stable operation of the blade and avoiding the risk of failure of the blade root.

[0049] According to the present application, the rough structure can be formed in many ways. In some embodiments, sandblasting can be used to form the roughness. Sandblasting has corresponding requirements for the shape of the component, which is more suitable for a flat surface. For heterogeneous components, the roughness may be uneven due to different spraying distances, thereby affecting the bonding strength. In order to improve the uniformity of the roughness, in other embodiments, the rough structure is formed by a demoulding cloth, and the surface roughness of the rough structure is relatively uniform. In an exemplary embodiment, the rough structure is formed by a plurality of convex hulls, and the upper surface of the convex hull forms a convex arc surface. Specifically, the roughness Ra of the rough structure formed by the demoulding cloth is between 6.3μm-15μm, and the rough structure formed by the demoulding cloth has good uniformity, so that the bonding strength of the wedge strip and the glass fiber reinforced plastic layer at the connection interface can be ensured, and the demoulding cloth can be arranged before the wedge strip is torn off before the blade mold, so as to ensure that the rough surface is free from contamination, thereby avoiding affecting the bonding strength.

[0050] For special-shaped components, if a release cloth is added to the entire surface, the pultrusion process is difficult to implement and is prone to quality defects. According to the present application, a rough structure is formed on the curved surface of the special-shaped component by a release cloth, and roughness can be formed at the rounded corners and flat surfaces of the special-shaped component by sandblasting, so that a preset rough structure can be formed on the surface of the special-shaped component to increase the bonding force with the glass fiber reinforced plastic layer.

[0051] In an embodiment, the surface of the blade member has a plurality of holes. In an exemplary embodiment, adjacent holes may be arranged in a certain regularity, for example but not limited to, may be arranged at equal intervals. Specifically, the hole diameter may be 1-3 mm, and the spacing between adjacent holes may be 5-20 mm.

[0052] In these embodiments, the surface of the blade component has multiple holes. During the blade manufacturing process, the product of the reaction between the glue-filling resin and the cross-linking product will fill the multiple holes on the surface of the blade component. The blade component and the fiberglass layer are connected to each other in an interlocking manner, thereby making the connection strength between the blade component and the fiberglass layer stronger.

[0053] According to a second aspect of the present application, a method for manufacturing a blade component is provided, wherein the blade component is used in a blade of a wind turbine generator set. The method for manufacturing the blade component includes the following steps S101 to S103.

[0054] Step S101 : mixing epoxy resin, anhydride curing agent and polyol in a predetermined ratio to obtain a mixture.

[0055] In the embodiment of the present application, the epoxy resin is a thermosetting resin. In an exemplary embodiment, the epoxy resin can be a bisphenol A epoxy resin or a bisphenol F epoxy resin. The anhydride curing agent can be composed of an anhydride curing agent and a accelerator, wherein the anhydride curing agent can be 4-methyltetrahydrophthalic anhydride, and the accelerator can be benzyltriethylammonium chloride. Polyols are alcohols containing two or more hydroxyl groups in the molecule. In an exemplary embodiment, the polyols can be polyethylene glycol. The hydroxyl group at one end of the polyol can attack the epoxy group of the epoxy resin, open-ring polymerize, and form a stable molecular chain, and the other end will form an active hydroxyl group on the surface of the blade component. During the production process of the blade, the active hydroxyl group on the surface of the blade component will continue to react with the group of the epoxy resin infused, so that the blade component can be connected to the glass fiber reinforced plastic layer through a chemical bond, thereby improving the bonding strength of the blade component and the glass fiber reinforced plastic layer.

[0056] Step S102, using the mixed material to impregnate the glass fiber.

[0057] In the embodiment of the present application, the glass fiber is a glass fiber with a sizing agent. In the process of manufacturing the blade component, the mixed material can be made to saturate the glass fiber as much as possible. In an exemplary embodiment, the traveling speed of the glass fiber in the mixed material can be controlled so that the glass fiber is saturated with the mixed material as much as possible. Specifically, the traveling speed of the glass fiber in the mixed material can be no more than 0.8 m / min.

[0058] Step S103, sintering the impregnated glass fiber to obtain a blade component made of a material having a plurality of active hydroxyl groups on the surface, wherein the material having a plurality of active hydroxyl groups on the surface is a cross-linked product of epoxy resin and polyols.

[0059] In an embodiment, after the glass fiber is infiltrated, the blade member of the material having a plurality of active hydroxyl groups on the surface can be obtained by controlling the parameters of the sintering process. In an exemplary embodiment, the sintering temperature can be 120-200° C., and the sintering time can be 4-10 minutes.

[0060] According to the present application, epoxy resin, anhydride curing agent and polyols are mixed in a predetermined ratio. The present application does not intentionally limit the order of adding epoxy resin, anhydride curing agent and polyols. In some embodiments, the order of adding the above-mentioned materials can be limited. Specifically, the step of obtaining the mixture includes first mixing the polyols and epoxy resin, and then adding the anhydride curing agent to the mixture of the polyols and epoxy resin to obtain the mixture.

[0061] In these embodiments, the polyols and epoxy resins are first mixed, and then the anhydride curing agent is added to the former mixture to form a mixed material, which can reduce the probability of the anhydride curing agent and the polyols reacting, avoid side reactions (for example, the anhydride curing agent and the polyols reacting), and thus avoid affecting the performance of the prepared blade component. In addition, limiting the order of adding materials can ensure the amount of cross-linked products formed in the blade component, providing a sufficient amount of active hydroxyl groups for the subsequent reaction with the potting resin.

[0062] In an exemplary embodiment, the epoxy resin, the anhydride curing agent and the polyol are mixed in a predetermined ratio. In an exemplary embodiment, the molar ratio of the epoxy resin, the anhydride curing agent and the polyol is 12: (12-11): 1. The model of the glass fiber can be 4800TEX, 2400TEX, 1200TEX, 600TEX.

[0063] In an embodiment, sintering is performed by step-wise heating, wherein the step-wise heating includes heating the impregnated glass fiber to an initial temperature and keeping the temperature for a preset time, and then heating it to a curing temperature, thereby obtaining a blade component having active hydroxyl groups on the surface. In an exemplary embodiment, the initial temperature may be 140-160°C, and the curing temperature may be 180-200°C. If the temperature is too low, incomplete curing may occur, affecting the quality of the formed blade component. If the temperature is too high, the reaction is too violent, and implosion may occur, resulting in whitening and powdering of the formed blade component.

[0064] In these embodiments, under the effect of temperature, the glass fiber can be better infiltrated, thereby ensuring the uniformity of the formed blade component. In addition, heating to the initial temperature and keeping the temperature for a preset time can timely discharge the gas or solvent in the mixture, and then heating to the curing temperature, thereby avoiding defects (such as bubbles, etc.) in the formed blade component, thereby ensuring the compactness of the prepared blade component and ensuring that the blade component has sufficient load-bearing capacity.

[0065] In the embodiment, the equivalent ratio of the epoxy resin to the polyol is 12:(0.9-1.1), the weight ratio of the epoxy resin to the anhydride curing agent is 100:(95-105), and the weight ratio of the epoxy resin to the glass fiber is 100:(14-25).

[0066] In the embodiment, the viscosity of the mixture is 500-1000 haPas, and the mixture is within a suitable viscosity range, which can ensure that the glass fiber is effectively impregnated. If the viscosity of the mixture is less than 500 haPas, the viscosity of the mixture is too small, which means that the ratio of the epoxy resin and the curing agent forming the mixture is not within a suitable range, which will cause the epoxy resin content in the impregnated glass fiber to account for a relatively small proportion, thereby affecting the performance of the prepared blade component. If the viscosity of the mixture is greater than 1000 haPas, the viscosity of the mixture is too high, which may cause the glass fiber to be unable to be fully impregnated by the mixture, so that the cross-linked products on the glass fiber of the blade component cannot be evenly distributed, and quality defects such as dry yarn and whitening are prone to occur.

[0067] In an embodiment, the method for manufacturing a blade component further comprises arranging a release cloth on the surface of the impregnated glass fiber before sintering, so as to obtain a blade component with a rough structure by removing the release cloth after solidification and molding.

[0068] In these embodiments, when manufacturing the blade component, a release cloth is arranged on the surface of the impregnated glass fiber, so that a blade component with a release cloth on the surface can be manufactured, and the release cloth can be removed when manufacturing the blade. On the one hand, the exposed rough structure on the surface of the blade component will make the bonding strength of the components inside the manufactured blade higher. On the other hand, the rough structure on the surface of the blade component is not contaminated, which can ensure the bonding strength to a certain extent.

[0069] According to a third aspect of the present application, a blade is provided, the blade comprising the blade component provided by the above-mentioned embodiments or comprising the blade component manufactured by the method for manufacturing the blade component provided by the above-mentioned embodiments. The blade also comprises a fiberglass layer connected to the outside of the blade component, wherein the fiberglass layer is formed by curing the fiber layer and the glue-injecting resin, and the fiberglass layer and the blade component form a product of the reaction of the glue-injecting resin and the cross-linking product on the contact surface.

[0070] According to the blade provided in the embodiment of the present application, the active hydroxyl groups on the surface of the blade component can be connected with the fiberglass layer on the contact surface through chemical reaction, and have extremely high connection strength, so that the multiple components inside the blade are seamlessly formed into one, which can avoid the problem of blade root failure due to unreliable connection interface, thereby ensuring the service life of the manufactured blade.

[0071] According to the present application, the potting resin can be selected from the potting resin in the wind power field, and the potting resin has groups that can react with the active hydroxyl groups on the surface of the blade component. In an embodiment, the potting resin includes a mixture of epoxy resin and amine curing agent. Both the epoxy resin and the amine curing agent in the potting resin can react with the active hydroxyl groups on the surface of the blade component, thereby further improving the adhesion of the connection interface. In an exemplary embodiment, the epoxy resin is a thermosetting resin, specifically, the epoxy resin can be a bisphenol A epoxy resin or a bisphenol F epoxy resin. The amine curing agent can be a polyetheramine or isophorone diamine. According to the fourth aspect of the present application, a method for manufacturing a blade is provided, wherein the method for manufacturing a blade comprises:

[0072] Step S201 : covering the outside of the blade component with a fiber ply to obtain a ply structure.

[0073] Step S202: using a potting resin to infiltrate the layer structure.

[0074] Step S203, sintering the laminate structure impregnated with the resin, and controlling the parameters of the sintering process to obtain a blade having a glass fiber reinforced plastic layer formed by curing the resin and the fiber laminate. The blade component is a blade component provided according to the above embodiments or a blade component manufactured according to the method for manufacturing a blade component provided according to the above embodiments, and a product of the reaction between the resin and the cross-linking product is formed on the contact surface of the glass fiber reinforced plastic layer and the blade component.

[0075] In the embodiment of the present application, the sintering temperature may be 40-100° C., and the sintering time may be 10-12 hours.

[0076] According to the present application, the blade component includes glass fiber and a material having a plurality of active hydroxyl groups on the surface filled in the gaps between the glass fibers, wherein the material having a plurality of active hydroxyl groups on the surface is a cross-linked product of epoxy resin and polyols.

[0077] According to the present application, the potting resin may be a potting resin in the wind power field, and the potting resin has a group that can react with the active hydroxyl group on the surface of the blade component. In an embodiment, the potting resin includes a mixture of an epoxy resin and an amine curing agent. Both the epoxy resin and the amine curing agent can react with the active hydroxyl group on the surface of the blade component, thereby further improving the bonding strength of the connection interface.

[0078] In an embodiment, the surface of the blade member has a plurality of pores, and the product of the reaction between the potting resin and the cross-linking product is filled in the plurality of pores on the surface of the blade member.

[0079] In these embodiments, the reaction product of the potting resin and the cross-linking product will fill multiple holes on the surface of the blade component, and the blade component and the fiberglass layer are connected to each other in an interlocking manner, thereby making the connection strength between the blade component and the fiberglass layer stronger.

[0080] The embodiments of the present application are described above, but those skilled in the art may make various modifications and variations to the embodiments of the present application without departing from the spirit and scope of the present application. However, it should be understood that, in the opinion of those skilled in the art, these modifications and variations will still fall within the spirit and scope of the embodiments of the present application defined by the claims.

Claims

1. A blade component, used in a blade of a wind turbine generator set, characterized in that: The blade component includes glass fiber and a material having multiple active hydroxyl groups on the surface filled in the gaps of the glass fiber. The material having multiple active hydroxyl groups on the surface is a cross-linked product of epoxy resin and polyols, and the surface of the blade component has active hydroxyl groups.

2. The blade member according to claim 1, characterized in that: The blade component is a wedge-shaped strip, and the weight of the cross-linked product accounts for 20%-25% of the total weight of the wedge-shaped strip.

3. The blade member according to claim 1, characterized in that The blade component is a blade main beam, and the weight of the cross-linked product accounts for 14%-20% of the total weight of the blade main beam.

4. The blade member according to claim 2, characterized in that: The wedge-shaped strip has an arc-shaped surface, and the arc-shaped surface has a rough structure.

5. The blade member according to claim 4, characterized in that The rough structure is formed by a release cloth.

6. The blade member according to claim 1, characterized in that The surface of the blade member has a plurality of holes.

7. A method for manufacturing a blade component, wherein the blade component is used in a blade of a wind turbine generator set, characterized in that: The method comprises the following steps: Mixing epoxy resin, anhydride curing agent and polyol in a predetermined ratio to obtain a mixture; impregnating glass fibers with the mixed material; The impregnated glass fiber is sintered to obtain a blade component made of a material having a plurality of active hydroxyl groups on the surface, wherein the material having a plurality of active hydroxyl groups on the surface is a cross-linked product of epoxy resin and polyols.

8. The method for manufacturing a blade component according to claim 7, characterized in that: The step of obtaining the mixed material comprises: The polyols and the epoxy resin are first mixed, and then the anhydride curing agent is added to the mixture of the polyols and the epoxy resin, so as to obtain the mixture.

9. The method for manufacturing a blade component according to claim 7, characterized in that: The sintering is carried out in a step-by-step heating method, and the step-by-step heating method includes: The soaked glass fiber is heated to an initial temperature and kept at the initial temperature for a preset time, and then heated to a curing temperature, so as to obtain a blade component with active hydroxyl groups on the surface.

10. The method for manufacturing a blade component according to claim 7, characterized in that: The equivalent ratio of the epoxy resin to the polyol is 12:(0.9-1.1), the weight ratio of the epoxy resin to the anhydride curing agent is 100:(95-105), and the weight ratio of the epoxy resin to the glass fiber is 100:(14-25).

11. The method for manufacturing a blade component according to claim 7, characterized in that: The viscosity of the mixture is 500-1000 millipascals.

12. The method for manufacturing a blade component according to claim 7, characterized in that: The method for manufacturing a blade component further comprises: Before sintering, a release cloth is arranged on the surface of the impregnated glass fiber, so that a blade component with a rough structure on the surface is obtained by removing the release cloth after solidification and molding.

13. A blade, characterized in that: The blade includes a blade component according to any one of claims 1 to 6 or a blade component made by the method for manufacturing a blade component according to any one of claims 7 to 12, and the blade also includes: a fiberglass layer connected to the outside of the blade component, the fiberglass layer is formed by curing a fiber layer and an injection molding resin, and a product of the reaction between the injection molding resin and the cross-linking product is formed on the contact surface between the fiberglass layer and the blade component.

14. The blade according to claim 13, characterized in that The potting resin comprises a mixture of epoxy resin and amine curing agent.

15. A method for manufacturing a blade, characterized in that: include: Wrapping a fiber ply on the outside of the blade component to obtain a ply structure; Infiltrating the laminate structure with a glue-injecting resin; The laminate structure impregnated with the resin is sintered, and the parameters of the sintering process are controlled to obtain a blade having a glass fiber reinforced plastic layer formed by curing the resin and the fiber laminate. Wherein, the blade component is a blade component according to any one of claims 1 to 6 or a blade component made by the method for manufacturing a blade component according to any one of claims 7 to 12, and the fiberglass layer and the blade component form a product of the reaction of the glue-filling resin and the cross-linking product on the contact surface.

16. The method for manufacturing a blade according to claim 15, characterized in that: The potting resin comprises a mixture of epoxy resin and amine curing agent.

17. The method for manufacturing a blade according to claim 15, characterized in that: The surface of the blade component has a plurality of holes, and the product of the reaction between the potting resin and the cross-linking product is filled in the plurality of holes.