Flexible heatable molded surface and preparation method thereof

Abstract

The invention discloses a flexible heatable molded surface and a preparation method thereof, the flexible heatable molded surface comprises a metal net layer, the metal net layer is of a pore structure and is formed by weaving springs and metal wires, and the metal net layer is used for a composite material supporting frame; the heat insulation layer covers the outer side of the metal net layer and is used for being connected with the metal net layer and insulating heat of the metal net layer at the same time; the electric heating layer is arranged on the upper plane of the metal net layer through the heat insulation layer, and the electric heating layer is used for heating the molded surface; the heat conduction layer is arranged on the upper plane of the electric heating layer and used for rapidly conducting heat of the electric heating layer to the surface layer. The composite material has flexibility, air tightness, aging resistance, electrical insulation, high and low temperature resistance and heatability at the same time, the effects of surface layer heating, bottom layer heat insulation and layer surface shape following can be achieved, preparation of different blade models is met, the production cost is effectively reduced, and the production efficiency is improved.

Description

Technical Field

[0001] The invention belongs to the technical field of flexible molding, and in particular relates to a flexible heatable molding surface and a preparation method thereof. Background Art

[0002] With the continuous development of society, the consumption of non-renewable energy such as coal and natural gas is increasing, and it is not a long-term solution for people to use them. At the same time, when these fossil energy sources are burned, they will pollute the environment and cause harm to the human body. In order to reduce the consumption of non-renewable energy, it has become an inevitable trend to vigorously develop new energy such as wind power generation.

[0003] At present, wind turbine blade molds are made of fiberglass. The problem is that the molds need to be constantly updated due to the continuous optimization of the blade structure. However, the manufacturing cycle of conventional molds is 30 days, and the manufacturing cost is high. They cannot be deformed. When the blade model changes, the blade shape cannot be adapted, which makes the mold idle and wastes resources. In order to avoid the current situation where different blade models require different molds, the mold model must be adjustable. At the same time, in order to meet the requirements for the use of the mold during the blade production process, it must have characteristics such as heatability, sealing, corrosion resistance, and a certain degree of rigidity. Therefore, it is necessary to improve and optimize the mold material. Summary of the invention

[0004] In order to at least partially solve the technical problems existing in the above-mentioned prior art, the present invention provides a flexible heatable surface and a preparation method thereof.

[0005] The flexible heatable profile of the present invention comprises:

[0006] A metal mesh layer, which is a porous structure and is woven from springs and metal wires. The metal mesh layer is used for the composite material support frame;

[0007] A heat insulation layer, the heat insulation layer is coated on the outside of the metal mesh layer, the heat insulation layer is used to connect the metal mesh layers and to insulate the metal mesh layers;

[0008] An electric heating layer, the electric heating layer is arranged on the plane of the metal mesh layer through the heat insulation layer, and the electric heating layer is used to heat the molding surface;

[0009] A heat-conducting layer is arranged on the upper plane of the electric heating layer, and is used for quickly conducting the heat of the electric heating layer to the surface layer.

[0010] Furthermore, in the above-mentioned flexible heatable surface, the spring in the metal mesh layer has an outer diameter of 8 mm, an inner diameter of 6 mm, the metal wire has a diameter of 1 mm, the maximum equivalent stress is 696 MPa, and the maximum displacement is 0.0211 mm.

[0011] Furthermore, in the above-mentioned flexible heatable surface, the heat insulation layer is made of silicone rubber with a heat-resistant temperature of above 160°C, and the coating thickness of the heat insulation layer is 1-2mm.

[0012] Furthermore, in the above-mentioned flexible heatable surface, the electric heating layer includes an electric heating wire, an electric heating insulation layer, a temperature sensor, a temperature controller and a bayonet base, the electric heating insulation layer is coated on the electric heating wire, the bayonet base is arranged on the metal mesh layer, the electric heating wire is arranged in an S shape on the bayonet base, the temperature sensor is arranged between the electric heating wires, and the temperature controller is used to control the heating temperature of the electric heating wire.

[0013] Furthermore, in the above-mentioned flexible heatable surface, the electric heating insulation layer is made of F46 material, with a heat resistance temperature of 205°C and a power frequency withstand voltage of 2000V.

[0014] Furthermore, in the above-mentioned flexible heatable surface, the electric heating wire is made of nickel alloy, has a diameter of 0.8 mm, a resistance value of 0.3Ω, an allowable temperature tolerance range of -50°C to +205°C, and a service life of ≥20000h.

[0015] Furthermore, in the above-mentioned flexible heatable surface, the bayonet base is arc-shaped with a radius of 10 mm and a height of 5 mm. A circular leakage groove is arranged in the middle of the bayonet base. The bayonet base is connected to the metal mesh layer through the circular leakage groove. The spacing between the bayonet bases is 20 mm. An arc-shaped groove is arranged around the arc of the bayonet base, and the electric heating wire is connected to the bayonet base through the arc-shaped groove.

[0016] Furthermore, in the above-mentioned flexible heatable surface, the heat-conducting layer is made of silicone rubber with heat-conducting filler added thereto, the thickness of the heat-conducting layer is 1 cm, and the heat-resistant temperature is above 160°C.

[0017] In another aspect of the present invention, a method for preparing a flexible heatable surface is provided, comprising the following steps:

[0018] S1: preparing a metal mesh layer by weaving a spring and a metal wire into a corresponding metal mesh layer;

[0019] S2: Prepare an electric heating layer, arrange the electric heating wire on the metal mesh layer, and perform a partition design. First, arrange the bayonet base on the metal mesh layer, and then wind the electric heating wire on the bayonet base by winding.

[0020] S3: Measure the size of the metal mesh layer, determine the size of the mold for preparing the composite material, lay a plastic plate on the bottom, surround it with plastic baffles of corresponding size, and seal the gaps in the baffles with sealant.

[0021] S4: Prepare the heat insulation layer, weigh an appropriate amount of heat insulation layer silicone rubber material, mix the AB components evenly, and then evacuate and degas in a vacuum box, and send it into the mold through a screw pump to immerse the metal mesh layer but not the electric heating wire.

[0022] S5: Prepare the thermal conductive layer. Before the thermal insulation layer silicone rubber is cured, weigh an appropriate amount of thermal conductive layer silicone rubber material, mix the AB components evenly, and then evacuate and degas in a vacuum box. Then, use a screw pump to pump the material into the mold to immerse the electric heating wire layer and wait for curing.

[0023] S6: After the heat-conducting layer silicone rubber is cured, remove the surrounding baffles and trim and beautify the rubber area.

[0024] The flexible heatable profile and the preparation method thereof of the present invention have the following advantages and beneficial effects:

[0025] The present invention has good flexibility, can provide heating for composite materials, can realize controllable heating temperature and controllable heating temperature in local areas, and can change the profile to meet the preparation of different blade models, effectively avoiding the problem of remaking blade molds, reducing production costs, and avoiding waste of resources. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the prior art descriptions. Obviously, the drawings in the following descriptions are only used to further understand the embodiments of the present invention and constitute a part of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work. In the drawings:

[0027] Figure 1 It is a schematic diagram of the hierarchical structure of the flexible heatable profile of the present invention;

[0028] Figure 2 It is a schematic diagram of the structure of the electric heating layer of the flexible heatable surface of the present invention.

[0029] Description of reference numerals:

[0030] 1: thermal conductive layer; 2: temperature sensor; 3: electric heating layer; 4: thermal insulation layer; 5: metal mesh layer; 6: electric heating wire; 7: bayonet base; 8: arc-shaped slot; 9: circular drain slot. DETAILED DESCRIPTION

[0031] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be clearly and completely described below in conjunction with the specific embodiments of the present invention and the corresponding drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0032] like Figure 1 to Figure 2 As shown, the flexible heatable profile of the present invention comprises:

[0033] The metal mesh layer 5 is a porous structure, which is woven from springs and metal wires. The metal mesh layer 5 is used for the composite material support frame;

[0034] The heat insulation layer 4 is coated on the outside of the metal mesh layer 5, and the heat insulation layer 4 is used to connect the metal mesh layer 5 and to insulate the metal mesh layer 5;

[0035] An electric heating layer 3, the electric heating layer 3 is arranged on a plane of the metal mesh layer 5 through a heat insulating layer 4, and the electric heating layer 3 is used to heat the molding surface;

[0036] The heat-conducting layer 1 is arranged on the upper plane of the electric heating layer, and is used for quickly conducting the heat of the electric heating layer 3 to the surface layer.

[0037] Furthermore, in the flexible heatable surface of the present invention, the spring in the metal mesh layer 5 has an outer diameter of 8 mm, an inner diameter of 6 mm, the metal wire has a diameter of 1 mm, the maximum equivalent stress is 696 MPa, and the maximum displacement is 0.0211 mm. The maximum equivalent stress and the maximum displacement in the metal mesh layer 5 are mainly concentrated at the edge of the metal mesh layer 5, thereby ensuring that the composite material surface does not deform due to human trampling, and at the same time has a certain stretchability, so that deformation and displacement will occur when there is sufficient external force.

[0038] Furthermore, in the flexible heatable surface of the present invention, the thermal insulation layer 4 is made of silicone rubber with a heat resistance temperature of more than 160°C. The thermal insulation layer 4 is coated with a thickness of 1-2mm, so that the thermal insulation layer 4 is tightly connected through the pore structure of the metal mesh layer 5. The silicone rubber material can ensure the stretchability of the metal mesh layer 5, and at the same time effectively prevent the heat of the heating layer from flowing to the metal mesh layer 5, thereby avoiding heat loss.

[0039] Furthermore, in the flexible heatable surface of the present invention, the electric heating layer 3 includes an electric heating wire 6, an electric heating insulation layer, a temperature sensor 2, a temperature controller and a bayonet base 7. The electric heating insulation layer is coated on the electric heating wire 6. The bayonet base 7 is arranged on the metal mesh layer 5. The electric heating wire 6 is arranged in an S shape on the bayonet base 7. The bayonet base 7 is used to fix the electric heating wire 6, which effectively ensures the height positioning of the electric heating wire 6. The temperature sensor 2 is arranged between the electric heating wires 6. The temperature controller is used to control the heating temperature of the electric heating wire 6. The heating temperature can be adjusted in real time and detected in real time by the temperature sensor 2, thereby meeting the requirements for the heating temperature and effectively maintaining the surface temperature at around 80°C.

[0040] Furthermore, in the flexible heatable surface of the present invention, the electric heating insulation layer is made of F46 material, with a heat resistance temperature of 205°C and a power frequency withstand voltage of 2000V, which effectively ensures the heating effect of the electric heating layer 3.

[0041] Furthermore, in the flexible heatable surface of the present invention, the electric heating wire 6 is made of nickel alloy, has a diameter of 0.8 mm, a resistance of 0.3Ω, an allowable temperature range of -50°C to +205°C, and a service life of ≥20000h, which effectively ensures the service life of the electric heating layer 3.

[0042] Furthermore, in the flexible heatable surface of the present invention, the bayonet base 7 is arc-shaped with a radius of 10 mm and a height of 5 mm. A circular leakage groove 9 is arranged in the middle of the bayonet base 7. The bayonet base 7 is connected to the metal mesh layer 5 through the circular leakage groove 9, and enters the circular leakage groove 9 when the insulation layer 4 is laid, thereby effectively ensuring the connection strength between the electric heating layer 3 and the metal mesh layer 5 through the insulation layer 4. The spacing between the bayonet bases 7 is 20 mm, thereby ensuring that the heating layer can be heated evenly. An arc-shaped groove 8 is arranged around the arc of the bayonet base 7, and the electric heating wire 6 is connected to the bayonet base 7 through the arc-shaped groove 8.

[0043] Furthermore, in the flexible heatable surface of the present invention, the heat conductive layer 1 is made of silicone rubber with added heat conductive filler, the thickness of the heat conductive layer 1 is 1 cm, and the heat resistance temperature is above 160°C, so that the heat of the electric heating layer 3 can be quickly conducted to the surface of the heat conductive layer 1 to heat the blade material.

[0044] In another aspect of the present invention, a method for preparing a flexible heatable surface is provided, comprising the following steps:

[0045] S1: Prepare a metal mesh layer by weaving it into a metal mesh layer using springs and metal wires, so that the maximum equivalent stress at the edge is 696MPa and the maximum displacement is 0.0211mm;

[0046] S2: Prepare an electric heating layer, arrange the electric heating wire on the metal mesh layer, and perform a partition design. First, arrange the bayonet base on the metal mesh layer, and then wind the electric heating wire on the bayonet base by winding.

[0047] S3: Measure the size of the metal mesh layer, determine the size of the mold for preparing the composite material, lay a plastic plate on the bottom, surround it with plastic baffles of corresponding size, and seal the gaps in the baffles with sealant.

[0048] S4: Prepare the heat insulation layer, weigh an appropriate amount of heat insulation layer silicone rubber material, mix the AB components evenly, and then evacuate and degas in a vacuum box, and send it into the mold through a screw pump to immerse the metal mesh layer but not the electric heating wire.

[0049] S5: Prepare the thermal conductive layer. Before the thermal insulation layer silicone rubber is cured, weigh an appropriate amount of thermal conductive layer silicone rubber material, mix the AB components evenly, and then evacuate and degas in a vacuum box. Then, use a screw pump to pump the material into the mold to immerse the electric heating wire layer and wait for curing.

[0050] S6: After the heat-conducting layer silicone rubber is cured, the surrounding baffles are removed and the periphery of the rubber is trimmed and beautified to complete the preparation of the flexible heatable surface.

[0051] In summary, compared with the prior art, the flexible heatable surface and the preparation method thereof of the present invention have the following advantages and beneficial effects: the present invention has good flexibility, and can provide heating to the composite material through the electric heating layer, and can realize controllable heating temperature and controllable heating temperature of the local area. At the same time, the metal mesh layer can change the surface to meet the preparation of different blade models, effectively avoiding the problem of remaking the blade mold, reducing production costs, and also avoiding waste of resources.

[0052] It should be noted that, in this article, unless otherwise clearly specified and limited, the term "connection" or its synonyms should be understood in a broad sense. For example, "connection" can be a fixed connection or a detachable connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances. Moreover, expressions such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. At the same time, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such a process, method, article or device. In addition, "front", "back", "left", "right", "upper" and "lower" in this article are all referenced to the placement state shown in the accompanying drawings.

[0053] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A flexible heatable profile, characterized in that: The flexible heatable profile comprises: A metal mesh layer, which is a porous structure and is woven from springs and metal wires. The metal mesh layer is used for the composite material support frame; A heat insulation layer, the heat insulation layer is coated on the outside of the metal mesh layer, the heat insulation layer is used to connect the metal mesh layers and to insulate the metal mesh layers; An electric heating layer, the electric heating layer is arranged on the plane of the metal mesh layer through the heat insulation layer, and the electric heating layer is used to heat the molding surface; A heat-conducting layer is arranged on the upper plane of the electric heating layer, and is used for quickly conducting the heat of the electric heating layer to the surface layer.

2. The flexible heatable profile according to claim 1, characterized in that: The spring in the metal mesh layer has an outer diameter of 8 mm, an inner diameter of 6 mm, the metal wire has a diameter of 1 mm, the maximum equivalent stress is 696 MPa, and the maximum displacement is 0.0211 mm.

3. The flexible heatable profile according to claim 1, characterized in that: The heat insulation layer is made of silicone rubber with a heat resistance temperature of more than 160°C. The heat insulation layer has a coating thickness of 1-2mm.

4. The flexible heatable profile according to claim 1, characterized in that: The electric heating layer includes an electric heating wire, an electric heating insulation layer, a temperature sensor, a temperature controller and a bayonet base. The electric heating insulation layer is coated on the electric heating wire. The bayonet base is arranged on the metal mesh layer. The electric heating wire is arranged in an S shape on the bayonet base. The temperature sensor is arranged between the electric heating wires. The temperature controller is used to control the heating temperature of the electric heating wire.

5. The flexible heatable profile according to claim 4, characterized in that: The electric heating insulation layer is made of F46 material, with a heat resistance temperature of 205°C and a power frequency withstand voltage of 2000V.

6. The flexible heatable profile according to claim 4, characterized in that: The electric heating wire is made of nickel alloy, has a diameter of 0.8 mm, a resistance value of 0.3Ω, an allowable temperature tolerance range of -50°C to +205°C, and a service life of ≥20000h.

7. The flexible heatable profile according to claim 4, characterized in that: The bayonet base is arc-shaped, with a radius of 10mm and a height of 5mm. A circular leakage groove is arranged in the middle of the bayonet base. The bayonet base is connected to the metal mesh layer through the circular leakage groove. The spacing between the bayonet bases is 20mm. An arc-shaped groove is arranged around the arc of the bayonet base. The electric heating wire is connected to the bayonet base through the arc-shaped groove.

8. The flexible heatable profile according to claim 1, characterized in that: The heat-conducting layer is made of silicone rubber with heat-conducting fillers added thereto. The thickness of the heat-conducting layer is 1 cm and the heat-resistant temperature is above 160° C.

9. A method for preparing a flexible heatable surface, characterized in that: include: S1: preparing a metal mesh layer by weaving a spring and a metal wire into a corresponding metal mesh layer; S2: Prepare an electric heating layer, arrange the electric heating wire on the metal mesh layer, and perform a partition design. First, arrange the bayonet base on the metal mesh layer, and then wind the electric heating wire on the bayonet base by winding. S3: Measure the size of the metal mesh layer, determine the size of the mold for preparing the composite material, lay a plastic plate on the bottom, surround it with plastic baffles of corresponding size, and seal the gaps in the baffles with sealant. S4: Prepare the heat insulation layer, weigh an appropriate amount of heat insulation layer silicone rubber material, mix the AB components evenly, and then evacuate and degas in a vacuum box, and send it into the mold through a screw pump to immerse the metal mesh layer but not the electric heating wire. S5: Prepare the thermal conductive layer. Before the thermal insulation layer silicone rubber is cured, weigh an appropriate amount of thermal conductive layer silicone rubber material, mix the AB components evenly, and then evacuate and degas in a vacuum box. Then, use a screw pump to pump the material into the mold to immerse the electric heating wire layer and wait for curing. S6: After the heat-conducting layer silicone rubber is cured, remove the surrounding baffles and trim and beautify the rubber area.

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