Shell structure, preparation method thereof, fan blade and wind generating set

Abstract

The invention provides a shell structure, a preparation method thereof, a fan blade and a wind generating set. The housing structure includes: a main beam; the outer skin is arranged on the upper surface of the main beam; the inner skin is arranged on the lower surface of the main beam; the bonding layer comprises a first bonding layer arranged between the upper surface of the main beam and the outer skin, and the first bonding layer comprises fiber fabric and bonding resin. According to the fan blade, the bonding strength between the main beam and the outer skin can be improved, so that the layering damage between the main beam and the outer skin can be reduced, and the service life of the fan blade is prolonged.

Description

Technical Field

[0001] The present invention relates to the technical field of wind power generation, and in particular to a shell structure, a preparation method thereof, a wind turbine blade and a wind power generator set. Background Art

[0002] The wind turbine blade is the main structure of the wind turbine generator set. The wind turbine blade includes two half shells (i.e., an upper shell and a lower shell) and a web disposed between the two half shells for supporting the two half shells. Each half shell includes a main beam and inner and outer skins disposed above and below the main beam.

[0003] The main beam is the main load-bearing structure of the blade, providing the blade with anti-bending and anti-torsion capabilities. At present, the main beam forming processes of wind turbine blades mainly include vacuum infusion forming process, prepreg forming process, wet hand lay-up forming process, pultrusion forming process, etc.

[0004] In the pultrusion process, pultruded plates are formed by pultrusion. When manufacturing the shell of the blade, multiple pultruded plates are stacked to form a main beam, and then layers forming the inner and outer skins are formed above and below the main beam composed of multiple pultruded plates, and finally the shell structure is formed by an integrated infusion molding process.

[0005] However, in the shell structure of existing wind turbine blades, delamination damage may occur between the main beam and the inner and outer skins (especially the outer skin), especially when the main beam is formed by pultruded plates, which is more likely to cause delamination damage between the pultruded plates and the inner and outer skins. This delamination damage will cause damage to the blades and affect the service life of the wind turbine blades. At present, it is necessary to lift special maintenance tools into the air to repair the blades after shutdown, which will affect the power generation efficiency and increase the maintenance cost. Summary of the invention

[0006] An object of the present invention is to provide a shell structure capable of reducing delamination damage between a main beam and an outer skin, a preparation method thereof, a wind turbine blade and a wind turbine generator set.

[0007] Another object of the present invention is to provide a shell structure capable of reducing delamination damage between the main beam and the inner skin, a preparation method thereof, a wind turbine blade and a wind turbine generator set.

[0008] According to one aspect of the present invention, there is provided a shell structure of a wind turbine blade, the shell structure comprising: a main beam; an outer skin, arranged on the upper surface of the main beam; an inner skin, arranged on the lower surface of the main beam; an adhesive layer, comprising a first adhesive layer arranged between the upper surface of the main beam and the outer skin, the first adhesive layer comprising a fiber fabric and an adhesive resin.

[0009] Optionally, the bonding layer further includes a second bonding layer disposed between the lower surface of the main beam and the inner skin, and the second bonding layer includes fiber fabric and bonding resin.

[0010] Optionally, the main beam includes a plurality of pultruded plates stacked on each other, the first adhesive layer is arranged between the uppermost pultruded plate among the plurality of pultruded plates and the outer skin, and the second adhesive layer is arranged between the lowermost pultruded plate among the plurality of pultruded plates and the inner skin.

[0011] Optionally, the fiber fabric comprises a chopped fiber mat.

[0012] Optionally, the first adhesive layer and the second adhesive layer further include nanoparticles dispersed on the chopped fiber mat.

[0013] Optionally, the nanoparticles include at least one of graphene, carbon nanotubes and nano-silicon dioxide, and the fibers in the chopped fiber mat (20a) are at least one of glass fibers and carbon fibers.

[0014] Optionally, each of the first adhesive layer and the second adhesive layer is provided with a single layer of the chopped strand mat.

[0015] Optionally, the main beam further includes a guide layer arranged between adjacent pultruded plates among the plurality of pultruded plates.

[0016] Optionally, the plurality of pultruded boards are at least one of glass fiber pultruded boards and carbon fiber pultruded boards.

[0017] Optionally, the topmost pultruded plate and / or the bottommost pultruded plate is a carbon fiber pultruded plate or a demolding cloth-free glass fiber pultruded plate, the outer skin includes multiple outer skin fabric layers, the inner skin includes multiple inner skin fabric layers, the outer skin fabric layer close to the topmost pultruded plate among the multiple outer skin fabric layers is a glass fiber fabric layer, and the inner skin fabric layer close to the bottommost pultruded plate among the multiple inner skin fabric layers is a glass fiber fabric layer.

[0018] According to another aspect of the present invention, a method for preparing a shell structure of a wind turbine blade is provided, the method comprising: laying an outer skin fabric layer on a mold; laying a first bonding layer on the outer skin fabric layer, the first bonding layer comprising a fiber fabric; laying a main beam layer on the first bonding layer; laying an inner skin fabric layer on the main beam layer; and pouring resin to solidify and form the outer skin fabric layer, the first bonding layer, the main beam layer and the inner skin fabric layer.

[0019] Optionally, the preparation method further comprises: laying a second bonding layer between the main beam layer and the inner skin fabric layer, the second bonding layer comprising a fiber fabric.

[0020] Optionally, the step of laying the main beam ply on the first adhesive ply includes: laying a plurality of pultruded plates, and inserting a guide cloth between adjacent pultruded plates among the plurality of pultruded plates.

[0021] Optionally, the fiber fabrics in the first bonding ply and the second bonding ply include chopped fiber mats, and the first bonding ply and the second bonding ply also include nanoparticles dispersed on the chopped fiber mats, and each of the first bonding ply and the second bonding ply is prepared by the following method: dissolving the nanoparticles in a solvent to form a nanoparticle solution, the concentration of the nanoparticles being 0.01-0.1 g / L; spraying the nanoparticle solution on the chopped fiber mat; and drying the chopped fiber mat sprayed with the nanoparticles.

[0022] According to another aspect of the present invention, a wind blade is provided, the wind blade comprising an upper shell and a lower shell combined with each other, the upper shell and / or the lower shell comprising the shell structure of the wind blade as described above.

[0023] According to another aspect of the present invention, a wind turbine generator set is provided, wherein the wind turbine generator set comprises the wind turbine blade as described above.

[0024] According to the present invention, by providing a first bonding layer between the main beam and the outer skin, the bonding strength between the main beam and the outer skin can be improved, thereby reducing the delamination damage between the main beam and the outer skin and improving the service life of the fan blade.

[0025] According to the present invention, by providing a second bonding layer between the main beam and the inner skin, the bonding strength between the main beam and the inner skin can be improved, thereby reducing the delamination damage between the main beam and the inner skin and improving the service life of the wind turbine blades.

[0026] According to the present invention, even if the main beam is formed by a pultruded plate, the bonding strength between the main beam and the outer skin and the inner skin can be improved by providing a first adhesive layer and a second adhesive layer, thereby reducing the risk of delamination failure.

[0027] According to the present invention, by providing a fiber fabric including chopped fiber mats, the crack propagation path during interface destruction can be increased based on the strong coupling mechanical load transfer mode of chopped fiber interweaving, thereby being more conducive to improving the interface bonding strength.

[0028] According to the present invention, by laying nanoparticle-modified chopped fiber mat between the main beam pultruded plate and the fiber fabric layer, the energy in the crack propagation process during interface damage can be further absorbed, and the interface performance of the pultruded plate main beam and the inner / outer skin fabric interface can be further improved.

[0029] According to the present invention, the preparation method of the nanoparticle modified chopped fiber mat is simple, and the weight of the mat itself is relatively small, which has little effect on the overall weight of the blade. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description in conjunction with the accompanying drawings, in which:

[0031] Figure 1 is a cross-sectional view of a fan blade;

[0032] Figure 2 It is a cross-sectional view of a part of the shell structure of a fan blade in the prior art;

[0033] Figure 3 This is a photo of the shell structure of the prior art showing delamination damage;

[0034] Figure 4 is a cross-sectional view of a portion of a shell structure of a wind turbine blade according to an embodiment of the present invention;

[0035] Figure 5 is a flow chart of a method for manufacturing a shell structure of a wind turbine blade according to an embodiment of the present invention;

[0036] Figure 6 According to an embodiment of the present invention Figure 5 A flow chart of a method for preparing a first bonding layer and a second bonding layer;

[0037] Figure 7 is a photograph of a first bond layup and a second bond layup according to an embodiment of the present invention.

[0038] Explanation of the symbols in the drawings: 1-outer skin, 2-pultruded plate, 3-guide layer, 4-inner skin, 100-fan blades, 110-upper shell, 111-outer skin, 112-inner skin, 113-core layer, 114-main beam, 115-trailing edge auxiliary beam, 120-lower shell, 121-outer skin, 122-inner skin, 123-core layer, 124-main beam, 125-trailing edge auxiliary beam, 130-web, 11-outer skin, 12-inner skin, 20-adhesive layer, 20a-chopped fiber mat, 20b-nanoparticles, 21-first adhesive layer, 22-second adhesive layer, 30-main beam, 31-pultruded plate, 32-guide layer. DETAILED DESCRIPTION

[0039] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. 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 creative work are within the scope of protection of the present invention.

[0040] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art. The terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0041] Figure 1 is a cross-sectional view of a fan blade. Figure 1 As shown, the wind blade 100 may include an upper shell 110 , a lower shell 120 , and a web 130 supported between the upper shell 110 and the lower shell 120 .

[0042] Specifically, the upper shell 110 may include an outer skin 111, an inner skin 112, and a main beam 114 sandwiched between the outer skin 111 and the inner skin 112. As required, the upper shell 110 may further include a core layer 113. The core layer 113 may be sandwiched between the outer skin 111 and the inner skin 112, and the core layer 113 may be divided into two parts in the chord direction by the main beam 114. As required, the upper shell 110 may further include a trailing edge auxiliary beam 115. The trailing edge auxiliary beam 115 may be disposed close to the trailing edge of the wind turbine blade 100.

[0043] The lower shell 120 may include an outer skin 121, an inner skin 122, and a main beam 124 sandwiched between the outer skin 121 and the inner skin 122. If necessary, the lower shell 120 may further include a core layer 123. The core layer 123 may be sandwiched between the outer skin 121 and the inner skin 122, and the core layer 123 may be divided into two parts in the chord direction by the main beam 124. If necessary, the lower shell 120 may further include a trailing edge auxiliary beam 125. The trailing edge auxiliary beam 125 may be disposed close to the trailing edge of the wind turbine blade 100 and disposed at a position corresponding to the trailing edge auxiliary beam 115 of the upper shell 110.

[0044] In the prior art, delamination failure is easy to occur between the main beam and the outer skin or the inner skin (especially the outer skin). This delamination failure is more serious when the main beam is formed by a pultruded plate.

[0045] Figure 2 FIG. 1 is a cross-sectional view of a portion of a shell structure of a wind turbine blade in the prior art, in which the main beam is formed by a pultruded plate. Figure 2As shown, in the prior art, the shell structure includes an outer skin 1, an inner skin 4, and a plurality of pultruded plates 2 constituting a main beam disposed between the outer skin 1 and the inner skin 4. A guide layer 3 is disposed between adjacent pultruded plates 2 to bond the adjacent pultruded plates 2 together.

[0046] Figure 3 This is a photo of the shell structure of the prior art showing delamination damage. Figure 3 As shown, in the shell structure of the fan blade in the prior art, as Figure 3 In the part indicated by the arrow in the figure, the outer skin is delaminated from the main beam and partially torn, causing the main beam to leak out. Therefore, external moisture will enter the inside of the fan blade through the torn part of the outer skin, seriously affecting the service life of the fan blade. The outer skin is closer to the outside of the blade and is more susceptible to the external environment, so it is more likely to be delaminated. This delamination will cause damage to the blade and affect the service life of the fan blade.

[0047] Fan blade housing structure

[0048] According to an embodiment of the present invention, a shell structure capable of reducing delamination damage between a main beam and an outer skin is provided. The shell structure may be a part of the upper shell 110 and / or the lower shell 120, for example, the structure of the upper shell 110 and / or the lower shell 120 corresponding to the main beam portion.

[0049] Figure 4 FIG. 1 is a cross-sectional view of a portion of a shell structure of a fan blade according to an embodiment of the present invention. Figure 4 As shown, the shell structure of the wind turbine blade according to an embodiment of the present invention may include: a main beam 30; an outer skin 11, which is arranged on the upper surface of the main beam 30; an inner skin 12, which is arranged on the lower surface of the main beam 30; an adhesive layer 20, including a first adhesive layer 21 arranged between the upper surface of the main beam 30 and the outer skin 11, and the first adhesive layer 21 may include a fiber fabric and an adhesive resin.

[0050] According to an embodiment of the present invention, by setting a first bonding layer 21 between the upper surface of the main beam 30 and the outer skin 11, the bonding strength between the main beam 30 and the outer skin 11 can be improved, thereby reducing the delamination damage between the main beam and the outer skin and improving the service life of the wind turbine blades.

[0051] According to an embodiment of the present invention, the adhesive layer 20 may further include a second adhesive layer 22 disposed between the lower surface of the main beam 30 and the inner skin 12, and the second adhesive layer 22 may include a fiber fabric and an adhesive resin. According to an embodiment of the present invention, by disposing the second adhesive layer 22 between the lower surface of the main beam 30 and the inner skin 12, the bonding strength between the main beam 30 and the inner skin 12 may be improved, thereby reducing the delamination damage between the main beam and the inner skin and improving the service life of the wind turbine blade.

[0052] According to an embodiment of the present invention, the main beam 30 may include a plurality of pultruded plates 31 stacked on each other, the first adhesive layer 21 is arranged between the uppermost pultruded plate 31 of the plurality of pultruded plates 31 and the outer skin 11, and the second adhesive layer 22 is arranged between the lowermost pultruded plate 31 of the plurality of pultruded plates 31 and the inner skin 12. As described above, when the main beam is formed by a pultruded plate, delamination failure is more likely to occur between the main beam and the outer skin. According to the present invention, even if the main beam 30 is formed by a pultruded plate 31, the bonding strength between the main beam 30 and the outer skin 11 and the inner skin 12 can be improved by providing the first adhesive layer 21 and the second adhesive layer 22, thereby reducing the risk of delamination failure. That is, when the main beam 30 is formed by a pultruded plate 31, the effect of improving the bonding strength is more significant. However, the present invention is not limited thereto, and an adhesive layer may also be provided between the main beam manufactured by other means and the inner and outer skins.

[0053] According to an embodiment of the present invention, the top pultruded plate 31 and / or the bottom pultruded plate 31 may be a carbon fiber pultruded plate or a mold release cloth-free glass fiber pultruded plate. When the top pultruded plate 31 and / or the bottom pultruded plate 31 are carbon fiber pultruded plates, it is beneficial to improve the strength. When the top pultruded plate 31 and / or the bottom pultruded plate 31 are mold release cloth-free glass fiber pultruded plates, it is beneficial to reduce costs.

[0054] In this case, the top pultruded plate 31 or the bottom pultruded plate 31 will be in direct contact with the fiber fabric of the outer skin 11 or the inner skin 12, resulting in lower interlayer bonding strength. According to the present invention, even if the pultruded plate 31 is a carbon fiber pultruded plate or a mold-free glass fiber pultruded plate, the bonding strength between the main beam 30 and the outer skin 11 and the inner skin 12 can be improved by setting the first adhesive layer 21 and the second adhesive layer 22, thereby reducing the risk of delamination damage. That is, when the top pultruded plate 31 and / or the bottom pultruded plate 31 are carbon fiber pultruded plates or mold-free glass fiber pultruded plates, the effect of improving the bonding strength is more significant. As an example, the top pultruded plate 31 and the bottom pultruded plate 31 can both be carbon fiber pultruded plates or mold-free glass fiber pultruded plates. As another example, one of the top pultruded plate 31 and the bottom pultruded plate 31 can be a carbon fiber pultruded plate, and the other can be a mold-free glass fiber pultruded plate.

[0055] However, the present invention is not limited thereto, and the uppermost pultruded board 31 and / or the lowermost pultruded board 31 may also be other fiber pultruded boards, for example, glass fiber pultruded boards with release cloth. In this case, the bonding strength can be further improved.

[0056] According to an embodiment of the present invention, the pultruded plate 31 between the top pultruded plate 31 and the bottom pultruded plate 31 may be a glass fiber pultruded plate or a carbon fiber pultruded plate, and the present invention does not impose any specific restrictions on this. In addition, the pultruded plate types of the multiple pultruded plates 31 may be the same or different, and the present invention does not impose any restrictions on this.

[0057] According to an embodiment of the present invention, Figure 4 As shown, the main beam 30 may further include a guide layer 32 disposed between adjacent pultruded plates 31 among the plurality of pultruded plates 31. The guide layer 32 may be formed by a guide cloth infused with resin. By providing the guide layer 32, the bonding strength between adjacent pultruded plates 31 may be improved.

[0058] According to an embodiment of the present invention, the outer skin 11 may be a resin impregnated fiber structure, and may include a plurality of outer skin fabric layers stacked on each other. The inner skin 12 may also be a resin impregnated fiber structure, and may include a plurality of inner skin fabric layers stacked on each other. The materials of the outer skin fabric layer and the inner skin fabric layer may be the same or different from each other, and the present invention does not impose specific restrictions on this. In addition, the materials of the plurality of outer skin fabric layers may be the same or different, and the materials of the plurality of inner skin fabric layers may be the same or different, and the present invention does not impose specific restrictions on this.

[0059] As an example, the outer skin fabric layer and / or the inner skin fabric layer may be glass fiber or carbon fiber. When the outer skin fabric layer and / or the inner skin fabric layer is glass fiber, it is beneficial to reduce the cost while ensuring the strength. When the outer skin fabric layer and / or the inner skin fabric layer is glass fiber, it is beneficial to further improve the strength.

[0060] According to an embodiment of the present invention, in order to reduce costs while ensuring strength, the outer skin fabric layer of the multiple outer skin fabric layers close to the top pultruded plate 31 is a glass fiber fabric layer, and the inner skin fabric layer of the multiple inner skin fabric layers close to the bottom pultruded plate 31 is a glass fiber fabric layer. In this case, when the top pultruded plate 31 and / or the bottom pultruded plate 31 is a carbon fiber pultruded plate or a mold-free glass fiber pultruded plate, if the top pultruded plate 31 and the outer skin fabric layer close to the top pultruded plate 31 are directly bonded, the bonding strength will be relatively low. At the same time, if the bottom pultruded plate 31 and the inner skin fabric layer close to the bottom pultruded plate 31 are directly bonded, the bonding strength will be relatively low. According to an embodiment of the present invention, by providing the first adhesive layer 21 and the second adhesive layer 22, the bonding strength between the top pultruded plate 31 and the outer skin fabric layer adjacent thereto and the bonding strength between the bottom pultruded plate 31 and the inner skin fabric layer adjacent thereto can be improved, thereby reducing the risk of delamination damage.

[0061] According to an embodiment of the present invention, the first adhesive layer 21 and the second adhesive layer 22 may include a fiber fabric and an adhesive resin. According to an embodiment of the present invention, the first adhesive layer 21 and the second adhesive layer 22 may be formed by laying a first adhesive ply and a second adhesive ply, respectively, and infusing the resin. The first adhesive ply and the second adhesive ply include a fiber fabric. The adhesive resin may be the same type as the resin impregnating the fiber fabric layer in the outer skin 11 and the inner skin 12. As an example, the adhesive resin may be a thermosetting resin or a thermoplastic resin. As an example, the adhesive resin may be an epoxy resin, a polyurethane resin, etc., and the present invention does not specifically limit this.

[0062] Figure 7 is a photograph of a first bonding ply and a second bonding ply according to an embodiment of the present invention. Figure 7 As shown, the fiber fabric may include a chopped fiber mat 20a. The chopped fiber mat is a thin sheet product made by chopped strands that are non-directionally combined together by chemical adhesives or mechanical action. As an example, the chopped fiber mat 20a may be a chopped glass fiber mat. However, the present invention is not limited thereto, and the chopped fiber mat 20a may also be a chopped fiber mat of other materials, for example, a chopped carbon fiber mat. Alternatively, the chopped fiber mat 20a may be a mixed mat of chopped glass fibers and chopped carbon fibers. According to an embodiment of the present invention, each of the first bonding layer 21 and the second bonding layer 22 may be provided with a single layer of the chopped fiber mat 20a. As an example, the length of the fibers in the chopped fiber mat 20a may be 1 mm to 20 mm, and the gram weight of the chopped fiber mat 20a may be 100 g / m 2 Up to 200g / m 2 .

[0063] According to an embodiment of the present invention, by providing a fiber fabric including chopped fiber mat 20a, the crack propagation path during interface destruction can be increased based on the strong coupling mechanical load transfer mode of chopped fiber interweaving, thereby being more conducive to improving the interface bonding strength.

[0064] The chopped fiber mat 20a according to the embodiment of the present invention may be a nanoparticle-modified chopped fiber mat. Figure 7 As shown, the first adhesive layer 21 and the second adhesive layer 22 may further include nanoparticles 20b dispersed on the chopped fiber mat 20a. The nanoparticles 20b may include at least one of graphene, carbon nanotubes, and nanosilicon dioxide. As an example, the diameter of the nanoparticles 20b is less than or equal to 100nm.

[0065] According to an embodiment of the present invention, by laying nanoparticle-modified chopped fiber mat between the pultruded board and the inner / outer skin fiber fabric layer, and then forming by resin infusion, the existing load transfer between the main beam of the pultruded board and the inner / outer skin fiber fabric layer, which only relies on interlayer shear, is changed. The strong coupling mechanical load transfer mode based on the interweaving of chopped fibers of the chopped fiber mat increases the path of crack propagation during interface damage. In addition, by adopting the method of nanoparticle modification, the energy in the crack propagation during interface damage can be further absorbed, and the interface performance of the interface between the main beam of the pultruded board and the inner / outer skin fabric can be further improved.

[0066] Therefore, laying nanoparticle-modified chopped fiber mat between the main beam pultruded plate and the fiber fabric layer can effectively improve the interface performance between the main beam pultruded plate and the fiber fabric layer and avoid damage between the main beam pultruded plate and the glass fiber fabric layer.

[0067] In addition, the preparation method of nanoparticle-modified chopped fiber mat is simple, and the weight of the mat itself is relatively small, which has little effect on the overall weight of the blade.

[0068] Table 1 shows the shear strength (in MPa) and fracture toughness (type I interlaminar fracture toughness) (in J / m 2 In Table 1, the pultruded board is a glass fiber pultruded board without mold release cloth.

[0069] Table 1

[0070]

[0071] As shown in Table 1, when the nanoparticle-modified chopped fiber mat is not set between the pultruded plate and the glass fiber fabric, the tensile shear strength of the pultruded plate + glass fiber fabric interface is 26.7 MPa; the fracture toughness GIC is 284.6 J / m 2 When nanoparticle-modified chopped fiber mat is placed between the pultruded plate and the glass fiber fabric, the tensile shear strength of the pultruded plate + nanoparticle-modified chopped fiber mat + glass fiber fabric interface is 52.1 MPa, which is nearly doubled; the fracture toughness GIC is 598.3 J / m 2 , nearly doubled.

[0072] In addition, when interlayer guide cloth is set between adjacent pultruded plates, the shear strength of the interface of pultruded plate + interlayer guide cloth + pultruded plate is 42.5MPa, which is greater than the shear strength of the interface of pultruded plate + glass fiber fabric; the fracture toughness GIC of the interface of pultruded plate + interlayer guide cloth + pultruded plate is 365.4, which is greater than the fracture toughness GIC of the interface of pultruded plate + glass fiber fabric. Therefore, by setting interlayer guide cloth between adjacent pultruded plates, the interface bonding force between adjacent pultruded plates can be improved, and the shear strength and fracture toughness GIC can be improved.

[0073] In addition, it can be seen from Table 1 that when the pultruded plate is in direct contact with the glass fiber fabric, the shear strength and fracture toughness GIC of the pultruded plate + glass fiber fabric interface are significantly lower than those of the pultruded plate + interlayer guide cloth + pultruded plate interface, resulting in easy interlayer damage at the pultruded plate + glass fiber fabric interface. According to an embodiment of the present invention, by providing an adhesive layer (e.g., nanoparticle-modified chopped fiber mat) between the pultruded plate and the inner / outer skin fabric layer, the interface performance between the pultruded plate and the inner / outer skin fabric layer can be improved, and the interlayer damage at the interface between the pultruded plate and the inner / outer skin fabric layer can be effectively avoided.

[0074] Method for preparing shell structure of fan blade

[0075] The following will be combined Figure 5 and Figure 6 A method for manufacturing a shell structure of a wind turbine blade according to an embodiment of the present invention is described. In the following description, contents that overlap with the above description will be omitted.

[0076] Figure 5 is a flow chart of a method for manufacturing a shell structure of a wind turbine blade according to an embodiment of the present invention, Figure 6 According to an embodiment of the present invention Figure 5 Flow chart of a method for preparing a first bonding layer and a second bonding layer.

[0077] like Figure 5 As shown, the preparation method of the shell structure of the wind turbine blade according to an embodiment of the present invention may include: laying an outer skin fabric layer on a mold (S11); laying a first bonding layer on the outer skin fabric layer (S12), the first bonding layer including a fiber fabric; laying a main beam layer on the first bonding layer (S13); laying an inner skin fabric layer on the main beam layer; and pouring resin (S16) to solidify and form the outer skin fabric layer, the first bonding layer, the main beam layer and the inner skin fabric layer.

[0078] The method for preparing the shell structure according to the embodiment of the present invention may further include laying a second bonding layer between the main beam layer and the inner skin fabric layer, wherein the second bonding layer includes a fiber fabric. That is, the method for preparing the shell structure according to the embodiment of the present invention may further include laying the second bonding layer on the main beam layer (S14) and laying the inner skin fabric layer on the second bonding layer (S15).

[0079] In step S11, an outer skin fabric layer is laid on a mold. The mold may be a special mold for producing a shell structure of a wind turbine blade. For example, the mold may be a mold for producing an upper shell and / or a lower shell of a wind turbine blade. The outer skin fabric layer may be provided in multiple layers, and the specific number of layers is not limited. The materials of the multiple outer skin fabric layers have been described above, and their detailed description will be omitted here.

[0080] In step S12, a first bonding layer is laid on the outer skin fabric layer. The first bonding layer may include a fiber fabric. Figure 7 As shown, the fiber fabric may include a chopped fiber mat 20a. The first bonding layer may also include nanoparticles 20b dispersed on the chopped fiber mat 20a. The nanoparticles 20b may include at least one of graphene, carbon nanotubes, and nano-silicon dioxide.

[0081] According to an embodiment of the present invention, the first bonding layer can be prepared by: dissolving the nanoparticles 20b in a solvent to form a nanoparticle solution, wherein the concentration of the nanoparticles 20b is 0.01-0.1 g / L; spraying the nanoparticle solution on the chopped fiber mat 20a; and drying the chopped fiber mat 20a sprayed with the nanoparticles 20b.

[0082] During the dissolution process, the solvent may be any solvent that has a good dispersion effect on the nanoparticles and is easily volatilized during the subsequent drying process, including but not limited to deionized water, ethanol, acetone, etc. In order to achieve a good dispersion effect, the concentration of the nanoparticles 20b is 0.01-0.1 g / L.

[0083] During the spraying process, the dispersed nanoparticles 20b can be evenly sprayed on the surface of the chopped fiber mat 20a.

[0084] During the drying process, a drying process may be performed at 60° C. to 80° C. to dry the chopped fiber mat 20 a sprayed with the nanoparticles 20 b and remove the solvent.

[0085] In step S13, the main beam ply is laid on the first bonding ply. As an example, step S13 may include laying a plurality of pultruded plates 31 and inserting a guide cloth between adjacent pultruded plates 31 in the plurality of pultruded plates 31.

[0086] In step S14, a second bonding ply is laid on the main beam ply. The structure and preparation method of the second bonding ply may be the same as that of the first bonding ply, and redundant description is omitted here.

[0087] In step S15, an inner skin fabric layer is laid on the second bonding layer. The inner skin fabric layer can be provided with multiple layers, and the specific number of layers is not limited. The materials of the multiple inner skin fabric layers have been described above, and the detailed description thereof will be omitted here.

[0088] According to an embodiment of the present invention, the method for preparing the shell structure can be performed together with the upper shell 110 or the lower shell 120 of the wind turbine blade. In this case, the outer skin fabric layer and the inner skin fabric layer in the method for preparing the shell structure can be the outer skin fabric layer and the inner skin fabric layer of the entire wind turbine blade. In addition, when preparing the wind turbine blade, other structures can be provided as needed, such as the core layer and the trailing edge auxiliary beam described above.

[0089] According to another embodiment of the present invention, a fan blade 100 is also provided. As described above, the fan blade 100 may include an upper shell 110 and a lower shell 120 combined with each other. The upper shell 110 and / or the lower shell 120 may include the shell structure of the fan blade described above.

[0090] According to another embodiment of the present invention, a wind turbine generator set may be provided. The wind turbine generator set may include the wind turbine blade as described above.

[0091] The shell structure of the wind turbine blade according to the embodiment of the present invention can achieve beneficial technical effects not limited to the following description.

[0092] According to the present invention, by providing a first bonding layer between the main beam and the outer skin, the bonding strength between the main beam and the outer skin can be improved, thereby reducing the delamination damage between the main beam and the outer skin and improving the service life of the fan blade.

[0093] According to the present invention, by providing a second bonding layer between the main beam and the inner skin, the bonding strength between the main beam and the inner skin can be improved, thereby reducing the delamination damage between the main beam and the inner skin and improving the service life of the wind turbine blades.

[0094] According to the present invention, even if the main beam is formed by a pultruded plate, the bonding strength between the main beam and the outer skin and the inner skin can be improved by providing a first adhesive layer and a second adhesive layer, thereby reducing the risk of delamination failure.

[0095] According to the present invention, by providing a fiber fabric including chopped fiber mats, the crack propagation path during interface destruction can be increased based on the strong coupling mechanical load transfer mode of chopped fiber interweaving, thereby being more conducive to improving the interface bonding strength.

[0096] According to the present invention, by laying nanoparticle-modified chopped fiber mat between the main beam pultruded plate and the fiber fabric layer, the energy in the crack propagation process during interface damage can be further absorbed, and the interface performance of the pultruded plate main beam and the inner / outer skin fabric interface can be further improved.

[0097] According to the present invention, the preparation method of the nanoparticle modified chopped fiber mat is simple, and the weight of the mat itself is relatively small, which has little effect on the overall weight of the blade.

[0098] While exemplary embodiments of the present invention have been described in detail with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the claims.

Claims

1. A shell structure of a fan blade, characterized in that: The housing structure comprises: Main beam (30); An outer skin (11) is arranged on the upper surface of the main beam (30); An inner skin (12) is arranged on the lower surface of the main beam (30); The bonding layer (20) comprises a first bonding layer (21) arranged between the upper surface of the main beam (30) and the outer skin (11), wherein the first bonding layer (21) comprises fiber fabric and bonding resin.

2. The housing structure according to claim 1, characterized in that: The bonding layer (20) further comprises a second bonding layer (22) arranged between the lower surface of the main beam (30) and the inner skin (12), wherein the second bonding layer (22) comprises a fiber fabric and a bonding resin.

3. The housing structure according to claim 2, characterized in that: The main beam (30) includes a plurality of pultruded plates (31) stacked on each other, the first adhesive layer (21) is arranged between the uppermost pultruded plate (31) among the plurality of pultruded plates (31) and the outer skin (11), and the second adhesive layer (22) is arranged between the lowermost pultruded plate (31) among the plurality of pultruded plates (31) and the inner skin (12).

4. The housing structure according to claim 2 or 3, characterized in that: The fiber fabric includes a chopped fiber mat (20a).

5. The housing structure according to claim 4, characterized in that: The first adhesive layer (21) and the second adhesive layer (22) further include nanoparticles (20b) dispersed on the chopped fiber mat (20a).

6. The housing structure according to claim 5, characterized in that: The nanoparticles (20b) include at least one of graphene, carbon nanotubes and nano-silicon dioxide, and the fibers in the chopped fiber mat (20a) are at least one of glass fibers and carbon fibers.

7. The housing structure according to claim 4, characterized in that: Each of the first adhesive layer (21) and the second adhesive layer (22) is provided with a single layer of the chopped strand mat (20a).

8. The housing structure according to claim 3, characterized in that: The main beam (30) further comprises a guide layer (32) arranged between adjacent pultruded plates (31) among the plurality of pultruded plates (31).

9. The housing structure according to claim 3, characterized in that: The plurality of pultruded plates (31) are at least one of glass fiber pultruded plates (31) and carbon fiber pultruded plates (31).

10. The housing structure according to claim 9, characterized in that: The uppermost pultruded plate (31) and / or the lowermost pultruded plate (31) are carbon fiber pultruded plates or mold-free glass fiber pultruded plates. The outer skin (11) includes a plurality of outer skin fabric layers, and the inner skin (12) includes a plurality of inner skin fabric layers, wherein the outer skin fabric layer close to the uppermost pultruded plate (31) among the plurality of outer skin fabric layers is a glass fiber fabric layer, and the inner skin fabric layer close to the lowermost pultruded plate (31) among the plurality of inner skin fabric layers is a glass fiber fabric layer.

11. A method for preparing a shell structure of a fan blade, characterized in that: The preparation method comprises: laying an outer skin fabric layer on the mold; Laying a first bonding ply on the outer skin fabric layer, wherein the first bonding ply comprises a fiber fabric; Laying the main beam ply on the first bonding ply; Laying an inner skin fabric layer on the main beam ply; Resin is poured to solidify and shape the outer skin fabric layer, the first adhesive ply, the main beam ply and the inner skin fabric layer.

12. The preparation method according to claim 11, characterized in that: The preparation method further includes: laying a second bonding ply between the main beam ply and the inner skin fabric layer, wherein the second bonding ply includes a fiber fabric.

13. The preparation method according to claim 11, characterized in that: The step of laying the main beam ply on the first adhesive ply comprises: laying a plurality of pultruded plates (31), and inserting a guide cloth between adjacent pultruded plates (31) among the plurality of pultruded plates (31).

14. The preparation method according to claim 12, characterized in that: The fiber fabrics in the first bonding layer and the second bonding layer include chopped fiber mats (20a), and the first bonding layer and the second bonding layer also include nanoparticles (20b) dispersed on the chopped fiber mats (20a). Wherein, each of the first bonding ply and the second bonding ply is prepared by the following method: Dissolving the nanoparticles (20b) in a solvent to form a nanoparticle solution, wherein the concentration of the nanoparticles (20b) is 0.01-0.1 g / L; spraying the nanoparticle solution onto the chopped fiber mat (20a); The chopped fiber mat (20a) sprayed with the nanoparticles (20b) is dried.

15. A fan blade, characterized in that: The wind blade (100) comprises an upper shell (110) and a lower shell (120) which are combined with each other, and the upper shell (110) and / or the lower shell (120) comprise the shell structure of the wind blade according to any one of claims 1 to 10.

16. A wind turbine generator set, characterized in that: The wind turbine generator set comprises the wind turbine blade according to claim 15.

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