Modularized thermoplastic web plate structure for wind power, manufacturing method of modularized thermoplastic web plate structure and wind power generation blade

Abstract

The invention relates to a modularized thermoplastic web plate structure for wind power, a manufacturing method of the modularized thermoplastic web plate structure and a wind power generation blade. The modularized thermoplastic web plate structure comprises a continuous thermosetting web plate flange fixedly connected with a wind power blade shell; the thermoplastic modular interlayer is arranged between the two continuous thermosetting web flanges, and the end part of the thermoplastic modular interlayer is fixedly connected with the continuous thermosetting web flanges. Compared with the prior art, recovery and stable production of the wind power generation blade web can be achieved, meanwhile, the cost of production parts is reduced, the product quality and performance are guaranteed, and potential pouring defects, poor manufacturing cost and the like are reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of wind turbines, and relates to a modular thermoplastic web structure for wind power, a manufacturing method thereof, and a wind turbine blade. Background Art

[0002] At present, the traditional method of making the web of wind turbine blades is to use thermosetting resin and vacuum infusion process, which takes a long time to produce and is prone to infusion defects, such as micro cracks in the web and poor infiltration. As the blades become larger and larger, the web molds also need to grow and expand accordingly, resulting in increased investment costs. At the same time, thermosetting webs cannot be recycled and reused, and products with all-thermoplastic webs have problems such as difficulty in preparation and poor interface performance.

[0003] For example, in the manufacturing method of the web for wind turbine blades disclosed in CN202110474817.2, fiber-reinforced composite materials are used to manufacture multiple web modules, the web modules include a flat plate body and multiple reinforcing members, and the multiple reinforcing members are connected to the flat plate body; and multiple web modules are connected together to form a web for wind turbine blades. For example, a wind turbine blade web and its forming method disclosed in patent CN 115807731A use pultruded parts and core materials for co-infusion, which is the same as the existing process and cannot control the infusion defects. In addition, the shear web disclosed in CN107923365 A uses discrete springs to fix the panel. The above patents all use thermosetting materials, and the webs cannot be recycled. For example, although patents US 11035339B2 and US10697425B2 use the design of thermoplastic webs, they cannot effectively solve the problem of interface performance and are difficult to use quickly. Summary of the invention

[0004] The purpose of the present invention is to provide a modular thermoplastic web structure for wind power, a manufacturing method thereof and a wind turbine blade, which can achieve stable production of the web of wind turbine blades, reduce the cost of production parts, while ensuring product quality stability and performance, reducing potential infusion defects and CoPQ (bad manufacturing cost), etc.

[0005] The purpose of the present invention can be achieved by the following technical solutions:

[0006] In one aspect, the present invention provides a modular thermoplastic web structure for wind power generation, comprising:

[0007] A continuous heat-set web flange fixedly connected to the wind blade shell;

[0008] and a thermoplastic modular interlayer, wherein the thermoplastic modular interlayer is arranged between the two continuous thermosetting web flanges, and the ends of the thermoplastic modular interlayer are fixedly connected to the continuous thermosetting web flanges.

[0009] Furthermore, the thermoplastic modular sandwich includes a core material layer located in the middle, and thermoplastic skin layers covering the surfaces of opposite sides of the core material layer.

[0010] Furthermore, the thermoplastic skin layer can be made of thermoplastic prepreg tape, or thermoplastic resin powder and dry fiber according to different layer structures. Specifically, the layer can be laid in a + / -45° manner, and then the thermoplastic skin layer can be prepared by continuous molding technology. The continuous molding here includes the molding process of a belt conveyor, a steel belt conveyor or a continuous molding machine.

[0011] Preferably, the thickness of the thermoplastic skin layer is 1-10 mm, and the thermoplastic resin powder used is one of polyimide, polyamide nylon, polycarbonate, polyether ketone, polyether ether ketone, polyether ketone ketone, polypropylene, polyethylene, polysulfone, polyvinyl chloride, polyurethane, polyacetal, polyether nitrile, polymethacrylate, polyphenylene sulfide, polylactic acid, and polystyrene.

[0012] In the above preferred embodiment, the thermoplastic prepreg tape is one or more of unidirectional prepreg tape, fabric prepreg tape, twill prepreg tape, biaxial prepreg tape and multiaxial prepreg tape, with a thickness of 0.1-2 mm and a fiber mass fraction of 40-95%. Here, the continuous fiber used in the thermoplastic prepreg tape can be one or more of glass fiber, ceramic fiber, metal fiber, carbon fiber, basalt fiber, regenerated fiber or synthetic fiber.

[0013] In the above more preferred embodiment, the thickness of the core material layer is 5-100 mm, and the core material used is one or more of balsa wood, PET, PA, PVC, PU, ​​PP, and PC;

[0014] Furthermore, the thermoplastic skin layer and the core material layer are fixedly connected by welding, gluing or adhesive film.

[0015] Furthermore, the thermoplastic modular sandwich comprises a plurality of unit modules, wherein the number of unit modules in the chord direction at the same position does not exceed 5, and two adjacent unit modules are bonded or welded and reinforced with a thermoplastic skin layer.

[0016] Furthermore, the cross-section of the continuous heat-setting web flange is in the shape of "π", "L" or "T". In addition, "the angle of the web flange can be 60° to 150°, and the width of the web flange can be 50-250mm, which follows the contour of the wind blade shell". It should be pointed out here that the web flange can be understood as consisting of a bottom plate fixedly connected to the wind turbine blade shell, and one or two side panels connected to the bottom plate as a whole. The angle of the web flange here is equivalent to the angle between the bottom plate and the side panel surface, and the width of the web flange is the width of the bottom plate.

[0017] When connecting with the thermoplastic modular sandwich, the "π"-shaped opening area can be connected and fixed by wrapping the thermoplastic modular sandwich on three sides.

[0018] Furthermore, the "π"-shaped opening width of the continuous thermosetting web flange exceeds that of the thermoplastic modular interlayer by 0 to 10 mm.

[0019] Furthermore, the continuous thermosetting web flange is formed by infusion or pultrusion of thermosetting resin and dry reinforcing fibers.

[0020] Furthermore, the thermosetting resin is one or more of epoxy resin, polyurethane resin, unsaturated polyester and vinyl resin.

[0021] Furthermore, the dry reinforcing fiber is one or more of glass fiber, ceramic fiber, metal fiber, carbon fiber, basalt fiber, regenerated fiber or synthetic fiber.

[0022] Furthermore, the continuous heat-setting web flange remains continuous in the axial direction, or is segmented according to the design structure of the wind blade, and the number of segments does not exceed 3. When the continuous heat-setting web flange is segmented, the production of each segment is continuous.

[0023] Furthermore, the thermoplastic modular interlayer is also subjected to surface pretreatment, and the surface pretreatment is performed by one or more of plasma, ultraviolet light irradiation, electron beam, sandblasting and gamma ray irradiation.

[0024] In another aspect, the present invention also provides a method for manufacturing a modular thermoplastic web structure, comprising the following steps:

[0025] (1) firstly prepare a thermoplastic skin layer using a thermoplastic prepreg tape, then compound the thermoplastic skin layer with the core material layer to obtain a thermoplastic modular sandwich, and then cut it to a suitable size;

[0026] (2) Using thermosetting resin and dry reinforcing fiber to prepare continuous thermosetting web flange;

[0027] (3) After surface pretreatment of the thermoplastic modular interlayer, the interlayer is fixed to a continuous heat-setting web flange;

[0028] Or including the following steps:

[0029] (A) firstly prepare a thermoplastic skin layer using a thermoplastic prepreg tape, then compound the thermoplastic skin layer with a core material layer to obtain a thermoplastic modular sandwich, and then cut it to a suitable size;

[0030] (B) After surface pretreatment of the thermoplastic modular sandwich, dry reinforced fiber plying is used in the web flange mold and the thermoplastic modular sandwich area, and then injection curing is performed to form the mold.

[0031] Or including the following steps:

[0032] (I) firstly preparing a thermoplastic skin layer by using a thermoplastic prepreg tape, then compounding the thermoplastic skin layer with a core material layer to obtain a thermoplastic modular sandwich, and then cutting it to a suitable size;

[0033] (II) After surface pretreatment of the thermoplastic modular sandwich, dry reinforced fiber plying is performed at the installation position of the wind blade shell and the thermoplastic modular sandwich area, followed by infusion curing and molding.

[0034] In a third aspect, the present invention further provides a wind power blade, comprising a wind blade shell and any one of the modular thermoplastic web structures for wind power as described above.

[0035] Compared with the prior art, the present invention adopts thermoplastic modular interlayer and continuous thermosetting web flange to form a web structure. The web flange adopts a thermosetting form. The web flange can be prefabricated by a split mold or co-injected with the blade shell to prepare the web flange. The surface pretreatment method is used, so that the web can be assembled by co-injection or structural adhesive bonding, etc., which has the following advantages:

[0036] (1) It solves the problem of stable and continuous production of web sandwich structure and also realizes the problem of more than 90% recyclability of thermoplastic web;

[0037] (2) The risk of bonding between the web flange and the shell is reduced, and the web flange angle of 60° to 150° and the web flange width of 50-250mm can be quickly produced, reducing the investment in web molds and corresponding sites;

[0038] (3) The connection strength problem of thermoplastic and thermosetting interfaces has been solved.

[0039] (4) Accelerate the use of modular thermoplastic webs in wind turbine blades. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 It is a schematic diagram of the main view of the modular thermoplastic web structure and the wind turbine blade when being installed;

[0041] Figure 2 It is a side view schematic diagram of the modular thermoplastic web structure and the wind turbine blade being installed;

[0042] Figure 3 Schematic diagram of the preparation of thermoplastic modular sandwich;

[0043] Figure 4 Schematic diagram of surface pretreatment for thermoplastic modular sandwich;

[0044] Figure 5It is a schematic diagram of the assembly of the continuous thermosetting web flange and the thermoplastic modular sandwich in the prefabrication form;

[0045] Figure 6 It is a schematic diagram of the assembly of the continuous thermosetting web flange and the thermoplastic modular interlayer by co-injection;

[0046] Figure 7 It is a schematic diagram of the assembly of the continuous thermosetting web flange, the wind turbine blade shell and the thermoplastic modular sandwich by co-injection;

[0047] Description of the markings in the figure:

[0048] 10-thermoplastic modular sandwich, 11-continuous thermosetting web flange, 12-first intermediate layer;

[0049] 21-thermoplastic prepreg tape, 22-thermoplastic skin layer, 23-core material layer, 24-second intermediate layer;

[0050] 31-third intermediate layer;

[0051] 40-Flange mold. DETAILED DESCRIPTION

[0052] The present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0053] In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship 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 orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", and "third" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance.

[0054] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it 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 it can be indirectly connected through an intermediate medium, or it can be the internal communication 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.

[0055] In the following implementation modes or examples, if there is no special description of functional components or structures, it means that they are all conventional components or conventional structures used in the art to achieve corresponding functions; if there is no special description of processing or preparation technology, it means that they are all conventional technologies in the art.

[0056] In order to achieve stable production and effective recycling of the web of a wind turbine blade, the present invention provides a modular thermoplastic web structure for wind turbines, comprising:

[0057] A continuous heat-set web flange 11 fixedly connected to the wind blade shell;

[0058] And a thermoplastic modular interlayer 10, wherein the thermoplastic modular interlayer 10 is arranged between the two continuous thermosetting web flanges 11, and the end portion is fixedly connected to the continuous thermosetting web flanges 11.

[0059] During specific assembly, Figure 1 and Figure 2 As shown, the continuous heat-setting web flange 11 can be sealed with conventional structural adhesive or resin to form a first intermediate layer 12 to achieve connection with the blade shell.

[0060] In some specific embodiments, the thermoplastic modular sandwich 10 includes a core material layer 23 located in the middle, and a thermoplastic skin layer 22 covering the surfaces of the core material layer 23 on opposite sides. Figure 3 As shown, two thermoplastic skin layers 22 are provided, which are respectively located on both sides of the core material layer 23. The thermoplastic skin layer 22 and the core material layer 23 can be connected by a second intermediate layer 24. The second intermediate layer 24 can be one or more of an adhesive film, a resin film or a thermoplastic prepreg tape.

[0061] In a more specific embodiment, the thermoplastic skin layer 22 here can be a multi-layer fiber tape layer, preferably made of thermoplastic prepreg tape 21 or thermoplastic resin powder and dry fiber according to different layer structures. Specifically, the layer can be laid in a + / -45° manner, and then the thermoplastic skin layer 22 can be prepared by continuous molding. The continuous molding here includes a molding process of a belt conveyor, a steel belt conveyor or a continuous molding machine.

[0062] In the above-mentioned more preferred embodiment, the thickness of the thermoplastic skin layer 22 is 1-10 mm. Specifically, the thermoplastic resin powder used can be one of polyimide, polyamide nylon, polycarbonate, polyether ketone, polyether ether ketone, polyether ketone ketone, polypropylene, polyethylene, polysulfone, polyvinyl chloride, polyurethane, polyacetal, polyether nitrile, polymethacrylate, polyphenylene sulfide, polylactic acid, and polystyrene.

[0063] In the above preferred embodiment, the thermoplastic prepreg tape 21 is one or more of a unidirectional prepreg tape, a fabric prepreg tape, a twill prepreg tape, a biaxial or multiaxial prepreg tape, and has a thickness of 0.1-2 mm and a fiber mass fraction of 40-95%. Here, the continuous fiber used in the thermoplastic prepreg tape 21 can be one or more of glass fiber, ceramic fiber, metal fiber, carbon fiber, basalt fiber, regenerated fiber or synthetic fiber.

[0064] In the above more preferred embodiment, the thickness of the core material layer 23 is 5-100 mm, and the core material used is one or more of balsa wood, PET, PA, PVC, PU, ​​PP, and PC.

[0065] In a more specific embodiment, the thermoplastic skin layer 22 and the core material layer 23 are fixedly connected by welding, gluing or adhesive film.

[0066] In some specific embodiments, the thermoplastic modular sandwich 10 includes a plurality of unit modules, wherein the number of unit modules in the chord direction at the same position does not exceed 5, and two adjacent unit modules are bonded or welded and reinforced with a thermoplastic skin layer 22 .

[0067] In some specific embodiments, the cross-section of the continuous thermosetting web flange 11 is "π"-shaped, "the web flange angle is 60° to 150°, the web flange width is 50-250mm, and it follows the contour of the wind blade shell". When connected with the thermoplastic modular interlayer 10, the "π"-shaped opening area can be connected and fixed by wrapping the thermoplastic modular interlayer 10 on three sides.

[0068] In a more specific embodiment, the "π"-shaped opening width of the continuous thermosetting web flange 11 exceeds the width of the thermoplastic modular interlayer by 0 to 10 mm.

[0069] In some specific embodiments, the continuous thermosetting web flange 11 is formed by infusion or pultrusion of thermosetting resin and dry reinforcing fibers.

[0070] In a more specific embodiment, the thermosetting resin is one of epoxy resin, polyurethane resin, unsaturated polyester and vinyl resin.

[0071] In a more specific embodiment, the dry reinforcing fiber is one or more of glass fiber, ceramic fiber, metal fiber, carbon fiber, basalt fiber, regenerated fiber or synthetic fiber.

[0072] In some specific embodiments, the continuous heat-setting web flange 11 remains continuous in the axial direction, or is segmented according to the design structure of the wind blade, and the number of segments does not exceed 3. When the continuous heat-setting web flange 11 is segmented, the production of each segment is continuous.

[0073] In some specific embodiments, the thermoplastic modular interlayer 10 and the continuous thermosetting web flange 11 may be connected by resin or structural adhesive to form a third intermediate layer 31 to achieve fixed connection. In particular, when resin connection is used, dry reinforcing fibers are laid on three sides of the thermoplastic modular interlayer 10, and then vacuum infusion or the like is used to cure and shape (to obtain the continuous thermosetting web flange 11), and the connection with the blade shell is achieved.

[0074] In some specific embodiments, such as Figure 4 As shown, the thermoplastic modular sandwich 10 is also subjected to surface pretreatment, which can activate the thermoplastic surface, thereby enhancing the interface performance and improving the connection stability effect between the continuous thermosetting web flange 11 and the thermoplastic modular sandwich 10.

[0075] Specifically, the surface pretreatment can be performed by one or more of plasma, ultraviolet light irradiation, electron beam, sandblasting and gamma ray irradiation.

[0076] On the other hand, the present invention also provides a method for manufacturing a modular thermoplastic web structure. Depending on the different connection methods between the continuous thermosetting web flange 11 and the thermoplastic modular interlayer 10, there can be at least two molding methods:

[0077] The first forming method adopts a continuous heat-setting web flange 11 prefabrication method, which may specifically include the following steps:

[0078] (1) First, a thermoplastic skin layer 22 is prepared using a thermoplastic prepreg tape 21, and then the thermoplastic skin layer 22 is compounded with a core material layer 23 to obtain a thermoplastic modular sandwich 10, and then the thermoplastic modular sandwich 10 is cut into a suitable size;

[0079] (2) using thermosetting resin and dry reinforcing fibers to prepare a continuous thermosetting web flange 11;

[0080] (3) After surface pretreatment of the thermoplastic modular interlayer 10, the interlayer is fixed to the continuous heat-setting web flange 11;

[0081] The second molding method adopts a method of co-injection of the continuous thermosetting web flange 11 and the thermoplastic modular interlayer 10, or a method of co-injection of the thermosetting web flange 11, the thermoplastic modular interlayer 10 and the blade shell, which may specifically include the following steps:

[0082] (A) firstly prepare a thermoplastic skin layer using a thermoplastic prepreg tape, then compound the thermoplastic skin layer with a core material layer to obtain a thermoplastic modular sandwich, and then cut it to a suitable size;

[0083] (B) After surface pretreatment of the thermoplastic modular sandwich, dry reinforced fiber plying is used in the web flange mold and the thermoplastic modular sandwich area, and then injection curing is performed to form the mold.

[0084] Or including the following steps:

[0085] (I) firstly preparing a thermoplastic skin layer by using a thermoplastic prepreg tape, then compounding the thermoplastic skin layer with a core material layer to obtain a thermoplastic modular sandwich, and then cutting it to a suitable size;

[0086] (II) After surface pretreatment of the thermoplastic modular sandwich, dry reinforced fiber plying is performed at the installation position of the wind blade shell and the thermoplastic modular sandwich area, followed by infusion curing and molding.

[0087] The above embodiments may be implemented individually or in any combination of two or more.

[0088] The above implementation is described in more detail below in conjunction with specific examples.

[0089] Comparative Example 1

[0090] Thermosetting web production

[0091] 1) Using dry fiber and dry core, laying them on the web mold, using the existing conventional vacuum infusion process, using epoxy 180 / 185 resin, biaxial 800 fiber and PET foam to prepare a thermosetting web, the curing temperature is 70 °C.

[0092] After testing, the tensile shear performance of the thermoset-thermoset (i.e. the interface between the thermoset web flange and the thermoset sandwich interlayer) interface is 35.3MPa.

[0093] Comparative Example 2

[0094] Continuous thermosetting web flange 11 is bonded to the thermoplastic modular sandwich 10:

[0095] 1) Using a nylon thermoplastic prepreg tape 21, laying it at + / -45°, and then continuously molding it to prepare a thermoplastic skin layer 22;

[0096] 2) The thermoplastic skin layer 22, the nylon film (i.e., the second intermediate layer 24) and the PET foam (i.e., the core material layer 23) are continuously molded to prepare a thermoplastic modular sandwich 10;

[0097] 3) If Figure 5As shown, a thermoplastic modular sandwich 10 is placed on a platform, and continuous thermosetting web flanges 11 are placed on both sides, fixed by a vacuum bag, and bonded and cured by an epoxy adhesive to form a third intermediate layer 31, thereby obtaining a modular thermoplastic web;

[0098] After testing, the tensile shear performance of the thermosetting-thermoplastic interface (i.e. the interface between the thermosetting web flange and the thermoplastic modular interlayer) without surface pretreatment is 12.9MPa.

[0099] Comparative Example 3

[0100] Continuous thermosetting web flange 11 and thermoplastic modular sandwich 10 are co-injected:

[0101] 1) Using a nylon thermoplastic prepreg tape 21, laying it at + / -45°, and then continuously molding it to prepare a thermoplastic skin layer 22;

[0102] 2) The thermoplastic skin layer 22, the nylon film (i.e., the second intermediate layer 24) and the PET foam (i.e., the core material layer 23) are continuously molded to prepare a thermoplastic modular sandwich 10;

[0103] 3) If Figure 6 As shown, a small web flange mold (i.e., flange mold 40) is used to lay biaxial 800 fibers on both sides of the thermoplastic skin layer 22, and a vacuum infusion process is adopted. Epoxy 180 / 185 resin is used with a curing temperature of 70°C to prepare a thermosetting web flange 11, which is then consolidated and formed with the thermoplastic modular interlayer 10 to obtain a modular thermoplastic web.

[0104] After testing, the tensile shear performance of the thermosetting-thermoplastic interface without surface pretreatment is 15.2MPa.

[0105] Embodiment 1:

[0106] Continuous heat-setting web flange 11 prefabrication:

[0107] 1) Using a nylon thermoplastic prepreg tape 21, laying it at + / -45°, and then continuously molding it to prepare a thermoplastic skin layer 22;

[0108] 2) The thermoplastic skin layer 22, the nylon film (i.e., the second intermediate layer 24) and the PET foam (i.e., the core material layer 23) are continuously molded to prepare a thermoplastic modular interlayer 10 (i.e., a sandwich structure); then, Figure 4 As shown, the thermoplastic skin layer 22 is treated with plasma (the gas used to generate the plasma is air, the discharge power is 300W, and the gas pressure is 0.3kPa), the treatment time is 30s, the treatment is performed twice, and the effective open time (i.e., the effective activation time after the surface treatment) is 2h;

[0109] 3) using a small web flange mold, laying biaxial 800 fibers, using existing vacuum infusion technology, using epoxy 180 / 185 resin, and curing temperature 70° C., to prepare a thermosetting web flange 11;

[0110] 4) If Figure 5 As shown, a thermoplastic modular sandwich 10 is placed on a platform, and continuous thermosetting web flanges 11 are placed on both sides, fixed by a vacuum bag, and bonded and cured by an epoxy adhesive to form a third intermediate layer 31, thereby obtaining a modular thermoplastic web; after testing, the tensile shear performance of the thermosetting-thermoplastic interface after surface pretreatment is 38.4MPa;

[0111] Embodiment 2:

[0112] Continuous thermosetting web flange 11 and plasma treated thermoplastic modular interlayer 10 are co-injected:

[0113] 1) Using a thermoplastic prepreg tape 21 made of polypropylene, laying it in layers at + / -45°, and then preparing a thermoplastic skin layer 22 through continuous molding;

[0114] 2) The thermoplastic skin layer 22, the nylon film (i.e., the second intermediate layer 24) and the PET foam (i.e., the core material layer 23) are continuously molded to prepare a thermoplastic modular sandwich 10;

[0115] 3) If Figure 4 As shown, the thermoplastic skin layer 22 is treated with plasma (the gas used to generate the plasma is air, the discharge power is 300W, and the gas pressure is 0.3kPa), the treatment time is 30s, the treatment is performed twice, and the effective open time (i.e., the effective activation time after the surface treatment) is 2h;

[0116] 4) If Figure 6 As shown, a small web flange mold (i.e., flange mold 40) is used to lay biaxial 800 fibers on both sides of the treated thermoplastic skin layer 22, and the existing vacuum infusion process is used. Epoxy 180 / 185 resin is used, and the curing temperature is 70°C to prepare a thermosetting web flange 11, and at the same time, it is consolidated and formed with the thermoplastic modular interlayer 10 to obtain a modular thermoplastic web. After testing, the tensile shear performance of the thermosetting-thermoplastic interface after surface pretreatment is 40.7MPa;

[0117] Embodiment 3:

[0118] The continuous thermosetting web flange 11 is co-injected with the sandblasted thermoplastic modular sandwich 10:

[0119] 1) Using a nylon thermoplastic prepreg tape 21, laying it at + / -45°, and then continuously molding it to prepare a thermoplastic skin layer 22;

[0120] 2) The thermoplastic skin layer 22, the nylon film (i.e., the second intermediate layer 24) and the PET foam (i.e., the core material layer 23) are continuously molded to prepare a thermoplastic modular sandwich 10;

[0121] 3) If Figure 4 As shown, the thermoplastic skin layer 22 is treated by sandblasting, the treatment time is 60 seconds, the treatment is performed once, and the effective open time is 3 hours;

[0122] 4) If Figure 7 As shown, after the wind turbine blade shell is thermoset, the thermoplastic modular interlayer is erected on the shell surface, and biaxial 800 fibers are laid on both sides of the treated thermoplastic skin layer 22. A vacuum infusion process is adopted, epoxy 180 / 185 resin is used, and the curing temperature is 70°C to prepare a thermosetting web flange 11, which is simultaneously consolidated and formed with the thermoplastic modular interlayer 10 to obtain a modular thermoplastic web. After testing, the tensile shear performance of the thermosetting-thermoplastic interface after surface pretreatment is 38.9MPa.

[0123] Embodiment 4:

[0124] Continuous thermosetting web flange 11 is co-injected with electron beam treated thermoplastic modular sandwich 10:

[0125] 1) Using a nylon thermoplastic prepreg tape 21, laying it at + / -45°, and then continuously molding it to prepare a thermoplastic skin layer 22;

[0126] 2) The thermoplastic skin layer 22, the nylon film (i.e., the second intermediate layer 24) and the PET foam (i.e., the core material layer 23) are continuously molded to prepare a thermoplastic modular sandwich 10;

[0127] 3) See Figure 4 As shown, the thermoplastic skin layer 22 is treated with an electron beam (beam current intensity of 10 mA, electron beam energy of 1.8 MeV), the treatment time is 45 s, the treatment is performed once, and the effective open time is 2 h;

[0128] 4) If Figure 7 As shown, after the wind turbine blade shell is thermoset, the thermoplastic modular interlayer is erected on the shell surface, and biaxial 800 fibers are laid on both sides of the treated thermoplastic skin layer 22. The existing vacuum infusion process is adopted, epoxy 180 / 185 resin is used, and the curing temperature is 70°C to prepare the thermosetting web flange 11, and at the same time, it is consolidated and formed with the thermoplastic modular interlayer 10 to obtain a modular thermoplastic web. After testing, the tensile shear performance of the thermosetting-thermoplastic interface after surface pretreatment is 39.3MPa.

[0129] Embodiment 5:

[0130] Continuous thermosetting web flange 11 is co-injected with gamma-ray treated thermoplastic modular interlayer 10:

[0131] 1) Using a nylon thermoplastic prepreg tape 21, laying it at + / -45°, and then continuously molding it to prepare a thermoplastic skin layer 22;

[0132] 2) The thermoplastic skin layer 22, the nylon film (i.e., the second intermediate layer 24) and the PET foam (i.e., the core material layer 23) are continuously molded to prepare a thermoplastic modular sandwich 10;

[0133] 3) If Figure 4 As shown, the thermoplastic skin layer 22 is treated with gamma rays (irradiation energy is 3.5 MeV), the treatment time is 45 seconds, the treatment is performed once, and the effective open time is 3 hours;

[0134] 4) If Figure 7 As shown, after the wind turbine blade shell is thermoset, the thermoplastic modular interlayer is erected on the shell surface, and biaxial 800 fibers are laid on both sides of the treated thermoplastic skin layer 22. The vacuum infusion process is adopted, epoxy 180 / 185 resin is used, and the curing temperature is 70°C to prepare the thermosetting web flange 11, and at the same time, it is consolidated with the thermoplastic modular interlayer 10 to obtain a modular thermoplastic web. After testing, the tensile shear performance of the thermosetting-thermoplastic interface after surface pretreatment is 37.7MPa.

[0135] Embodiment 6:

[0136] Continuous thermosetting web flange 11 and UV-treated thermoplastic modular interlayer 10 are co-injected:

[0137] 1) Using a nylon thermoplastic prepreg tape 21, laying it at + / -45°, and then continuously molding it to prepare a thermoplastic skin layer 22;

[0138] 2) The thermoplastic skin layer 22, the nylon film (i.e., the second intermediate layer 24) and the PET foam (i.e., the core material layer 23) are continuously molded to prepare a thermoplastic modular sandwich 10;

[0139] 3) If Figure 4 As shown, the thermoplastic skin layer 22 is treated with ultraviolet light (wavelength of 350nm, power of 25W), the treatment time is 100s, the treatment is 2 times, and the effective open time is 2h;

[0140] 4) If Figure 7As shown, after the wind turbine blade shell is thermoset, the thermoplastic modular interlayer is erected on the shell surface, and biaxial 800 fibers are laid on both sides of the treated thermoplastic skin layer 22. A vacuum infusion process is adopted, epoxy 180 / 185 resin is used, and the curing temperature is 70°C to prepare a thermosetting web flange 11, which is simultaneously consolidated and formed with the thermoplastic modular interlayer 10 to obtain a modular thermoplastic web. After testing, the tensile shear performance of the thermosetting-thermoplastic interface after surface pretreatment is 33.9MPa.

[0141] The epoxy 180 / 185 resin used in the above comparative examples and embodiments is a two-component epoxy resin (i.e., TECHSTORM 180 / 185) commonly used in the field for vacuum infusion of fan blades. In the specific implementation process, technicians in this field can also choose other types or brands of epoxy resins according to actual needs, or thermosetting resins such as polyurethane resins, unsaturated polyesters and vinyl resins.

[0142] In summary, the surface pretreatment effect of the prepared thermoplastic modular interlayer was tested and divided into three experimental groups and six control groups. The control group was not pretreated, and the six experimental groups were subjected to surface pretreatment under different parameter conditions.

[0143] Table 1 Experiment Interface Type Processing Tensile shear performance Comparative Example 1 Thermosetting-Thermosetting-Co-infusion No preprocessing 35.3MPa Comparative Example 2 Thermosetting-Thermoplastic-Adhesive No preprocessing 12.9MPa Comparative Example 3 Thermoset-Thermoplastic-Co-Infusion No preprocessing 15.2MPa Example 1 Thermosetting-Thermoplastic-Adhesive Plasma pretreatment 38.4MPa Example 2 Thermoset-Thermoplastic-Co-Infusion Plasma pretreatment 40.7MPa Example 3 Thermoset-Thermoplastic-Co-Infusion Sandblasting pretreatment 38.9MPa Example 4 Thermoset-Thermoplastic-Co-Infusion Electron beam pretreatment 39.3MPa Example 5 Thermoset-Thermoplastic-Co-Infusion Gamma ray pretreatment 37.7MPa Example 6 Thermoset-Thermoplastic-Co-Infusion UV pretreatment 33.9MPa

[0144] Combined with the above content, it can be seen that after the surface of the thermoplastic skin is pre-treated by plasma, the performance of its thermosetting-thermoplastic interface is greatly improved, which makes it easier to connect and assemble the thermosetting web flange and the thermoplastic skin by co-injection or bonding to prepare the web for wind power.

[0145] It can be seen that the present invention can significantly improve the surface energy of the product by pre-treating the same nylon or polypropylene surface, thereby improving the thermoplastic and thermosetting interface performance, thereby realizing the production of modular thermoplastic webs. Therefore, the present invention adopts a combination of continuous thermosetting flanges and modular thermoplastic sandwiches, and uses a continuous molding continuous equipment production method. On the one hand, it can realize the continuous production of web sandwiches and effectively reduce quality defects; on the other hand, the continuous thermosetting web flange can use a smaller mold or use the blade shell to achieve conventional bonding or co-injection methods to complete the bonding with the shell and reduce the investment in the mold; on the other hand, the use of efficient surface treatment technology can significantly improve the performance of the thermosetting and thermoplastic interfaces and ensure the reliability of the product.

[0146] The above description of the embodiments is to facilitate the understanding and use of the invention by those skilled in the art. It is obvious that those skilled in the art can easily make various modifications to these embodiments and apply the general principles described herein to other embodiments without creative work. Therefore, the present invention is not limited to the above embodiments, and improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the present invention should be within the scope of protection of the present invention.

Claims

1. A modular thermoplastic web structure for wind power, characterized in that: include: A continuous heat-set web flange fixedly connected to the wind blade shell; and a thermoplastic modular interlayer, wherein the thermoplastic modular interlayer is arranged between the two continuous thermosetting web flanges, and the ends of the thermoplastic modular interlayer are fixedly connected to the continuous thermosetting web flanges.

2. A modular thermoplastic web structure for wind power according to claim 1, characterized in that: The thermoplastic modular sandwich includes a core material layer located in the middle, and thermoplastic skin layers covering the surfaces of the opposite sides of the core material layer; The thermoplastic skin layer is made of thermoplastic prepreg tape, thermoplastic film, thermoplastic / thermosetting mixed or thermoplastic resin powder and dry fiber according to different layer structures.

3. A modular thermoplastic web structure for wind power according to claim 2, characterized in that: The thickness of the thermoplastic skin layer is 1-10 mm, and the thermoplastic resin used is one or more of polyimide, polyamide nylon, polycarbonate, polyether ketone, polyether ether ketone, polyether ketone ketone, polypropylene, polyethylene, polysulfone, polyvinyl chloride, polyurethane, polyacetal, polyether nitrile, polymethacrylate, polyphenylene sulfide, polylactic acid, and polystyrene; The thermoplastic prepreg tape is one or more of a unidirectional prepreg tape, a fabric prepreg tape, a twill prepreg tape, a biaxial prepreg tape or a multiaxial prepreg tape, and has a thickness of 0.1-2 mm and a fiber mass fraction of 40-95%; The thickness of the core material layer is 5-100 mm, and the core material used is one or more of balsa wood, PET, PA, PVC, PU, ​​PP, and PC; The thermoplastic skin layer and the core material layer are fixedly connected by welding, gluing or adhesive film.

4. A modular thermoplastic web structure for wind power according to claim 2, characterized in that: The thermoplastic modular sandwich comprises a plurality of unit modules, wherein the number of unit modules in the chord direction at the same position does not exceed 5, and two adjacent unit modules are bonded or welded and reinforced with a thermoplastic skin layer.

5. A modular thermoplastic web structure for wind power according to claim 1, characterized in that: The cross section of the continuous heat-set web flange is "π", "L" or "T" shaped, with an angle of 60° to 150° and a width of 50-250mm, and is in accordance with the contour of the wind blade shell; The "π"-shaped opening width of the thermosetting web flange exceeds the thermoplastic modular interlayer by 0 to 10 mm.

6. A modular thermoplastic web structure for wind power according to claim 1, characterized in that: The thermosetting web flange is formed by infusion or pultrusion of thermosetting resin and dry reinforcing fibers; The thermosetting resin is one of epoxy resin, polyurethane resin, unsaturated polyester and vinyl resin; The dry reinforcing fiber is one or more of glass fiber, ceramic fiber, metal fiber, carbon fiber, basalt fiber, regenerated fiber or synthetic fiber.

7. A modular thermoplastic web structure for wind power according to claim 1, characterized in that: The continuous heat-setting web flange remains continuous in the axial direction, or is segmented according to the design structure of the wind blade. When the heat-setting web flange is segmented, the production of each segment is continuous.

8. A modular thermoplastic web structure for wind power according to claim 1, characterized in that: The thermoplastic modular interlayer is also subjected to surface pretreatment, and the surface pretreatment is carried out by one or more of plasma, ultraviolet light irradiation, electron beam, sandblasting and gamma ray irradiation.

9. The method for manufacturing a modular thermoplastic web structure for wind power according to any one of claims 1 to 8, characterized in that: The following steps are involved: (1) firstly prepare a thermoplastic skin layer using a thermoplastic prepreg tape, then compound the thermoplastic skin layer with the core material layer to obtain a thermoplastic modular sandwich, and then cut it to a suitable size; (2) Using thermosetting resin and dry reinforcing fiber to prepare continuous thermosetting web flange; (3) After surface pretreatment of the thermoplastic modular interlayer, the interlayer is fixed to a continuous heat-setting web flange; Or including the following steps: (A) firstly prepare a thermoplastic skin layer using a thermoplastic prepreg tape, then compound the thermoplastic skin layer with a core material layer to obtain a thermoplastic modular sandwich, and then cut it to a suitable size; (B) after surface pretreatment of the thermoplastic modular sandwich, dry reinforced fiber plying is applied to the web flange mold and the thermoplastic modular sandwich area, followed by infusion curing molding; Or including the following steps: (I) firstly preparing a thermoplastic skin layer by using a thermoplastic prepreg tape, then compounding the thermoplastic skin layer with a core material layer to obtain a thermoplastic modular sandwich, and then cutting it to a suitable size; (II) After surface pretreatment of the thermoplastic modular sandwich, dry reinforced fiber plying is performed at the installation position of the wind blade shell and the thermoplastic modular sandwich area, followed by infusion curing and molding.

10. A wind power blade, comprising a wind blade shell and a modular thermoplastic web structure for wind power as claimed in any one of claims 1 to 8.

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