Web, manufacturing method thereof, blade and wind generating set

Abstract

The invention relates to a web plate and a manufacturing method thereof, a blade and a wind generating set, the web plate comprises a core material, the core material extends in the first direction, the core material is provided with a first surface, a second surface and a third surface, the first surface and the second surface are oppositely arranged in the second direction, the third surface is connected between the first surface and the second surface, and the first direction and the second direction intersect; the flanging structure is connected with the end of the side where the third surface is located, extends towards the two sides in the second direction and comprises a plurality of sub-structures arranged on the sides, away from each other, of the first surface and the second surface. Each substructure comprises a first extension part, a second extension part and a connecting layer which is clamped between the first extension part and the second extension part and extends along the first direction, and in the first direction, the orthographic projection of the first extension part and the orthographic projection of the second extension part are at least partially crossed with each other. According to the web plate, the cost can be reduced, and the structural strength and reliability can be improved.

Description

Technical Field

[0001] The present application relates to the technical field of wind power generation, and in particular to a web and a manufacturing method thereof, a blade and a wind power generator set. Background Art

[0002] With the development of wind turbine generator sets, the capacity of existing single-unit wind turbine generator sets has gradually increased. Correspondingly, the size of each component in the unit has also gradually increased. As the blades become larger, the load they bear is also increasing. In order to improve the structural strength and stability of the blades, the blades in existing wind turbines are usually bonded with a web structure inside. In order to improve the bonding strength, the web is usually provided with flanges on both sides of the web where it is bonded to the shell of the blade to expand the bonding area. However, as the load increases, cracks are prone to appear in the flange structure of the web, especially in the corner area, and once the cracks appear, they are prone to extend to the structural adhesive layer, resulting in a decrease in bonding quality and then bonding failure.

[0003] Therefore, there is an urgent need for a web that can inhibit the propagation of cracks between plies and improve the strength and reliability of the flange structure, as well as a corresponding manufacturing method, blade, wind turbine generator set, etc. Summary of the invention

[0004] The embodiments of the present application provide a web and a manufacturing method thereof, a blade and a wind turbine generator set. The web can suppress the propagation of interlaminar cracks and improve reliability.

[0005] In the first aspect, according to an embodiment of the present application, a web is proposed, comprising: a core material extending along a first direction, the core material having a first surface, a second surface and a third surface connected therebetween arranged opposite to each other in a second direction, the first direction and the second direction being arranged to intersect; a flanging structure arranged at one side end portion where the third surface is located and extending to both sides along the second direction, the flanging structure comprising a plurality of substructures respectively arranged on the first surface and the second surface side away from each other, each substructure comprising a first extension portion, a second extension portion and a connecting layer sandwiched therebetween and extending along the first direction, in the first direction, the orthographic projection of the first extension portion and the orthographic projection of the second extension portion at least partially intersect with each other.

[0006] According to one aspect of the embodiment of the present application, in a first direction, the first extension portions and the second extension portions are alternately arranged, and the orthographic projection of the first extension portion intersects with the orthographic projection of the second extension portion to form an intersection, and the intersection is located between the connecting layer and the core material.

[0007] According to one aspect of the embodiment of the present application, the flanging structure also includes a first main body portion and a second main body portion, the first main body portion and the first extension portion are interconnected to form a first layer, and the second main body portion and the second extension portion are interconnected to form a second layer; the first surface and the second surface are both sequentially stacked with the first main body portion and the second main body portion.

[0008] According to one aspect of the embodiment of the present application, each first ply includes a plurality of first extensions, each second ply includes a plurality of second extensions, and the plurality of first extensions and the plurality of second extensions are arranged at intervals along the first direction.

[0009] According to one aspect of an embodiment of the present application, the first laminate includes a first sub-laminate arranged on a first surface and a second sub-laminate arranged on a second surface. In a first direction, the first extension portion located in the first sub-laminate and the first extension portion located in the second sub-laminate are staggered and alternately arranged.

[0010] According to one aspect of the embodiment of the present application, in the first direction, the extension dimensions of the plurality of first extension portions and the plurality of second extension portions are all the same.

[0011] According to one aspect of an embodiment of the present application, the web further includes an end reinforcement layer, which is disposed between the third surface and the first ply, the end reinforcement layer at least partially covers the third surface, and extends to cover at least one of the first surface and the second surface.

[0012] According to one aspect of an embodiment of the present application, the flanging structure includes a plurality of first plies and a plurality of second plies, the first plies are arranged in sequence along a first direction, and the second plies are arranged in sequence along the first direction; in a direction perpendicular to a third surface, the orthographic projections of the plurality of first plies form a first pattern, and the first pattern covers the orthographic projection of the third surface.

[0013] According to one aspect of the embodiment of the present application, the web is symmetrically arranged relative to the first reference plane, and the first reference plane and the third surface are parallel to each other.

[0014] In the second aspect, according to an embodiment of the present application, a method for manufacturing a web is proposed, comprising: providing a core material, the core material extending along a first direction and having a first surface, a second surface and a third surface connected to each other in a second direction; providing a plurality of first plies, the first plies comprising a first main body portion and a first extension portion connected to each other; laying the first plies, laying the first main body portion on the first surface and the second surface respectively, so that the first extension portion extends along the first direction and at least partially covers the third surface; arranging a connecting layer on a side of the first extension portion away from the core material, so that the connecting layer extends along the first direction, and in a direction perpendicular to the third surface, the orthographic projection of the connecting layer is staggered and spaced from the core material; providing a plurality of second plies, the second plies comprising a second main body portion and a second extension portion connected to each other; laying the second plies, laying the plurality of second main bodies respectively on a side of the first main body portion located on opposite sides of the core material away from the core material, and the second extension portion is arranged to cross the first extension portion and cover at least a portion of the connecting layer.

[0015] According to one aspect of the embodiment of the present application, the step of laying the first layer further includes: adjusting the setting position of the first extension portion so that adjacent first extension portions are connected to the first main body portions arranged on the first surface and the second surface in the first direction.

[0016] According to one aspect of an embodiment of the present application, the step of providing a core material and the step of providing a plurality of first layers also include: providing an end reinforcement layer, laying the end reinforcement layer on the third surface, and making the end reinforcement layer at least partially cover at least one of the first surface and the second surface.

[0017] According to one aspect of an embodiment of the present application, the step of providing a core material further includes: providing a mold and placing the core material in the mold; after the step of laying the second layer, the step further includes: pouring filler into the mold and curing it to obtain a web.

[0018] In a third aspect, a blade is proposed according to an embodiment of the present application, comprising the web in any embodiment of the first aspect.

[0019] In a fourth aspect, according to an embodiment of the present application, a wind turbine generator set is proposed, comprising the blades in any embodiment of the third aspect.

[0020] The web provided in the embodiment of the present application includes a core material and a flange structure arranged at one end of the core material, wherein the flange structure includes substructures extending to opposite sides respectively, each substructure includes a first extension portion, a connecting layer and a second extension portion which are stacked, and in the extension direction of the web core material, the orthographic projections of the first extension portion and the second extension portion intersect with each other. By cross-arranging the ply structures in the flange, the propagation of cracks after bonding can be effectively prevented, and separation between plies can be avoided, thereby improving the reliability of the web. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The features, advantages and technical effects of exemplary embodiments of the present application will be described below with reference to the accompanying drawings.

[0022] Figure 1 is a schematic structural diagram of a web provided by an embodiment of the present application;

[0023] Figure 2 is a schematic structural diagram of a first layer provided by an embodiment of the present application;

[0024] Figure 3 is a schematic structural diagram of a second layer provided by an embodiment of the present application;

[0025] Figure 4 is a flow chart of a method for manufacturing a web provided by one embodiment of the present application;

[0026] Figure 5 yes Figure 4 A schematic structural diagram of step S1 in the manufacturing method shown;

[0027] Figure 6 yes Figure 4 A schematic structural diagram of step S3 in the manufacturing method shown;

[0028] Figure 7 yes Figure 4 A schematic structural diagram of step S4 in the manufacturing method shown;

[0029] Figure 8 yes Figure 4 A schematic structural diagram of step S6 in the manufacturing method shown;

[0030] Fig. 9 is a flow chart of a method for manufacturing a web provided by another embodiment of the present application;

[0031] Fig.10 It is a structural schematic diagram of a separated generator set provided in one embodiment of the present application.

[0032] in:

[0033] 100-web plate; 200-wind turbine generator set;

[0034] 10-core material; 20-flange structure; 30-end reinforcement layer;

[0035] 11-first surface; 12-second surface; 13-third surface; 21-substructure; 22-first ply; 23-second ply;

[0036] 211 - first extension portion; 212 - connection layer; 213 - second extension portion; 214 - first main body portion; 215 - second main body portion;

[0037] X-first direction; Y-second direction. DETAILED DESCRIPTION

[0038] The features and exemplary embodiments of various aspects of the present application will be described in detail below. In the detailed description below, many specific details are proposed to provide a comprehensive understanding of the present application. However, it is obvious to those skilled in the art that the present application can be implemented without the need for some of these specific details. The following description of the embodiments is only to provide a better understanding of the present application by illustrating examples of the present application. In the accompanying drawings and the following description, at least some of the known structures and technologies are not shown to avoid unnecessary ambiguity in the present application; and, for clarity, the size of some structures may be exaggerated. In addition, the features, structures or characteristics described below may be combined in one or more embodiments in any suitable manner.

[0039] The directional words appearing in the following description are all directions shown in the figures, and do not limit the specific structures in the molding mold and molding method of this application. In the description of this application, it should also be noted that, unless otherwise clearly specified and limited, the meaning of "multiple" is more than two, and the terms "installation" and "connection" 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 directly connected or indirectly connected; the directions or positional relationships indicated by the terms "upper", "lower", "left", "right", "inside", "outside", etc. are only for the convenience of describing this application and simplifying the description, and do not indicate or imply 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 a limitation on this application. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to the specific circumstances.

[0040] In addition, the terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0041] With the development of technology in the field of wind power generation, the unit capacity of existing wind turbines has been increasing, and the structural dimensions of its components have also gradually increased accordingly. Taking the blades as an example, as the length of the blades increases, the requirements for their own structural strength and stability have also gradually increased. Existing blades are usually composed of shells on both sides that are interlocked with each other. In order to improve the structural stability and strength of the blades, a web is usually provided in the cavity formed by the shell enclosure to strengthen them. The web is usually connected to the blade body by bonding, and in order to make the bonding more stable, the end of the web to be bonded is usually provided with a flange to expand the bonding area.

[0042] On this basis, the applicant found that the flange structure of the existing web is usually obtained by stacking multiple layers of ply materials and then pouring them into shape. Its structure has certain risks, which can easily lead to cracks between the plies of the flange structure under fatigue or load limit conditions, and the cracks may extend and expand to the surroundings, and may eventually expand to the entire interface, resulting in bonding failure at the web flange position. At the same time, due to the certain curvature of the blade body, the flange structure of the existing web usually has a distinction between the main bonding side and the auxiliary bonding side, and the two sides are asymmetrical, so when bearing load, the load distribution is also uneven, which is prone to damage and failure caused by stress concentration in the adhesive layer.

[0043] In order to solve the above problems, the embodiments of the present application propose a web and a manufacturing method thereof, a blade and a wind turbine generator set, wherein the web can effectively suppress the expansion of cracks by adjusting the setting method of the ply.

[0044] It can be understood that the following embodiments of the present application are only described by applying the flange structure in the web to the blades of a wind turbine, but the web provided in the embodiments of the present application is not limited to the following embodiments, and can also be used in other occasions where the web is bonded and needs to bear loads, and protect it.

[0045] In order to better understand this application, Figures 1 to 10 The web and its manufacturing method, blades, and wind turbine generator set provided in the present application are described in detail.

[0046] Please also read Figures 1 to 3 , Figure 1 is a schematic diagram of the structure of a web provided in one embodiment of the present application, Figure 2 is a schematic diagram of the structure of the first layer provided by an embodiment of the present application, Figure 3 It is a schematic diagram of the structure of the second layer provided in one embodiment of the present application.

[0047] In the first aspect, according to an embodiment of the present application, a web 100 is proposed, comprising a core material 10 and a flanging structure 20, wherein the core material 10 extends along a first direction X, and the core material 10 has a first surface 11, a second surface 12 and a third surface 13 connected therebetween, which are arranged opposite to each other in a second direction Y, and the first direction X and the second direction Y are arranged to intersect; the flanging structure 20 is arranged at one side end where the third surface 13 is located and extends to both sides along the second direction Y, and the flanging structure 20 includes a plurality of substructures 21 respectively arranged on the first surface 11 and the second surface 12 away from each other, each substructure 21 includes a first extension portion 211, a second extension portion 213 and a connecting layer 212 sandwiched therebetween and extending along the first direction X, and in the first direction X, the orthographic projection of the first extension portion 211 and the orthographic projection of the second extension portion 213 at least partially intersect with each other.

[0048] The embodiment of the present application provides a web 100, which includes a core material 10 and a flange structure 20 laid on one end of the core material 10. The core material 10 is used to provide the main support. In order to reduce the weight of the web 100 on the basis of reliable strength, the core material 10 can be made of balsa wood, PVC (Polyvinylchloride) plastic, PET (polyethylene glycol terephthalate) plastic, etc., which are commonly used in wind turbine blades. The present application does not make any specific limitation on this.

[0049] The core material 10 extends along the first direction X. When installed in the blade, the extension direction of the core material 10 should be the same as the extension direction of the blade. At the same time, the cross-sectional shape of the core material 10 can be rectangular to facilitate processing and to ensure structural stability when subjected to force. The core material 10 has two opposite side surfaces in the second direction Y, namely, a first surface 11 and a second surface 12, and a third surface 13 is connected between the two surfaces, namely, the first surface 11, the third surface 13, and the second surface 12 are connected in sequence.

[0050] On this basis, a flange structure 20 is provided at the end of the third surface 13 of the core material 10, and the flange structure 20 includes a plurality of substructures 21 extending from the end to both sides in the second direction Y, and these substructures 21 form flange surfaces to be bonded. Specifically, each substructure 21 includes a first extension portion 211, a second extension portion 213 and a connecting layer 212, wherein the connecting layer 212 extends along the same extension direction as the core material 10, that is, the first direction X, and the first extension portion 211 and the second extension portion 213 are respectively provided on the upper and lower sides of the connecting layer 212.

[0051] Furthermore, the first extension portion 211 and the second extension portion 213 are staggered in the first direction X, and the two portions sandwich the connection layer 212 from both sides. In addition, in the first direction X, the orthographic projections of the first extension portion 211 and the second extension portion 213 at least partially overlap and intersect with each other, that is, in the partial area not connected to the connection layer 212, the extension tracks of the orthographic projections of the two portions form at least one intersection.

[0052] Exemplarily, the first extension portion 211 and the second extension portion 213 can extend from the third surface 13 and one of the first surface 11 and the second surface 12, respectively, and cross each other to form an interlocking structure, thereby effectively blocking the cracks generated between different layer structures on the inner side of the intersection position, preventing the cracks from extending outward, and ensuring the reliability of the flange structure 20 after bonding.

[0053] In some optional embodiments, in the first direction X, the first extension portion 211 and the second extension portion 213 may be arranged alternately, or one of them may be continuously extended and the other may be arranged at intervals, and the present application does not make any specific limitation on this. The orthographic projection of the first extension portion 211 and the orthographic projection of the second extension portion 213 intersect to form an intersection, and the intersection is located between the connecting layer 212 and the core material 10.

[0054] The first extension part 211 and the second extension part 213 in the embodiment of the present application can be arranged alternately to form a more uniform and reliable force-bearing structure. As mentioned above, the orthographic projections of the first extension part 211 and the second extension part 213 in the first direction X intersect with each other to form an intersection, and two intersections can be formed symmetrically at positions close to the first surface 11 and the second surface 12. In the second direction Y, the intersection formed by the orthographic projection can be located between the connecting layer 212 and the core material 10. At this time, the interlayer cracks appearing at the end of the core material 10 can be limited between the two intersections, thereby preventing the cracks from continuing to extend outward to the entire flange structure 20, thereby causing the flange structure 20 to have a bonding failure problem.

[0055] In some optional embodiments, the flange structure 20 also includes a first main body portion 214 and a second main body portion 215. The first main body portion 214 and the first extension portion 211 are interconnected to form a first layer 22, and the second main body portion 215 and the second extension portion 213 are interconnected to form a second layer 23. The first surface 11 and the second surface 12 are both sequentially stacked with the first main body portion 214 and the second main body portion 215.

[0056] In addition to the portion extending from the end portion where the third surface 13 is located to both sides, the flange structure 20 in the embodiment of the present application also includes a portion of the structure covering the first surface 11 and the second surface 12. Specifically, it includes a first main body portion 214 and a second main body portion 215 connected to the first extension portion 211 and the second extension portion 213, respectively. The first main body portion 214 and the second main body portion 215 can be stacked on each other and are simultaneously arranged on the first surface 11 and the second surface 12.

[0057] As mentioned above, the partial structure of the flange structure 20 extending on both sides relative to each other in the second direction Y is provided with a first extension portion 211 and a second extension portion 213 whose orthographic projections of the first direction X intersect with each other, and both are respectively connected to the two stacked main body portions, and the first main body portion 214 of the two main body portions is arranged closer to the core material 10.

[0058] On this basis, in order to achieve the cross interlocking of the two, the first extension part 211 and the second extension part 213 can be respectively set as strip structures extending outward from their respective main parts, and the two are alternately arranged in the first direction and staggered. Taking the side substructure 21 close to the first surface 11 as an example, the first extension part 211 can extend from the first main part 214 covering the second surface 12 to the bottom of the connecting layer 212, and the second extension part 213 passes through between the core material 10 and the connecting layer 212, and extends from the first main part 214 covering the first surface 11 to the top of the connecting layer 212, forming an alternately arranged interlocking structure.

[0059] Alternatively, one of the first extension portion 211 and the second extension portion 213 may be continuously extended for a longer distance in the first direction X. Taking the continuous extension of the first extension portion 211 as an example, a plurality of vias may be provided in the first extension portion 211 at intervals. For the substructure 21 on one side of the first surface 11, the first extension portion 211 also extends from the first main body portion 214 covering the second surface 12 to the bottom of the connection layer 212, and in the second direction Y, the vias thereon should correspond to the position of the first surface 11, so that the second extension portion 213 extending from the first main body portion 214 covering the first surface 11 passes through the vias and extends to the upper side of the connection layer 212 to form an interlocking structure. In this embodiment, the present application does not specifically limit which of the first extension portion 211 and the second extension portion 213 is continuously extended, and it only needs to be able to form the required interlocking structure.

[0060] It is understandable that the first ply 22 and the second ply 23 may be single-layer structures, or both plies may be composed of multiple layers of the same shape and size stacked on top of each other to provide the required strength. The material of the first ply 22 and the second ply 23 may be biaxial cloth or other materials commonly used as skins in blades, and this application does not impose any specific limitation on this, as long as the corresponding strength requirements can be met.

[0061] In some optional embodiments, each first ply 22 includes a plurality of first extension portions 211 , each second ply 23 includes a plurality of second extension portions 213 , and the plurality of first extension portions 211 and the plurality of second extension portions 213 are arranged along the first direction X at intervals.

[0062] The first extension portions 211 and the second extension portions 213 in the embodiment of the present application may be arranged alternately and spaced apart in the first direction X, and each main body portion may be simultaneously connected to a plurality of extension portions spaced apart in the first direction X. Specifically, the first main body portion 214 may extend a certain distance along the first direction X and be connected to a plurality of strip-shaped first extension portions 211, and these first extension portions 211 are spaced apart from each other in the first direction X. Similarly, the second main body portion 215 may also be simultaneously connected to a plurality of second extension portions 213.

[0063] It can be understood that in the embodiment where the first extension portion 211 and the second extension portion 213 are arranged alternately and staggered with each other, the spacing between adjacent first extension portions 211 should be greater than or equal to the width of the second extension portion 213 arranged in the spacing area. Correspondingly, the spacing between adjacent second extension portions 213 should be greater than or equal to the width of the first extension portion 211 passing through the spacing area to ensure that the two can form the required interlocking flange structure 20 without interfering with each other.

[0064] In some optional embodiments, the first laminate 22 includes a first sub-laminate disposed on the first surface 11 and a second sub-laminate disposed on the second surface 12. In the first direction X, the first extension portion 211 located in the first sub-laminate and the first extension portion 211 located in the second sub-laminate are staggered and alternately disposed.

[0065] The first surface 11 and the second surface 12 in the embodiment of the present application are both paved with a layer structure formed by a first main body portion 214 and a second main body portion 215 stacked together, wherein the first layer 22 covering the first surface 11 and the second layer 23 covering the second surface 12 together constitute a substructure 21 close to the second surface 12 side, and correspondingly, the first layer 22 covering the second surface 12 and the second layer 23 covering the first surface 11 together constitute a substructure 21 close to the first surface 11 side.

[0066] On this basis, each first extension portion 211 at least partially covers the third surface 13, that is, the first ply 22 covering the first surface 11 is recorded as a first sub-ply, and the first extension portion 211 in the first sub-ply is bent from the top of the first surface 11 and extends in a direction close to the second surface 12 to form a substructure 21 on one side of the second surface 12. The first ply 22 covering the second surface 12 is recorded as a second sub-ply, and its extension direction is opposite to that of the former.

[0067] Thus, the first extension part 211 in the first sub-layer and the first extension part 211 in the second sub-layer extend toward each other, and can be staggered and arranged alternately in the first direction X. This arrangement can form an interlocking structure on the third surface 13 along the first direction X, i.e., the span direction of the blade to be bonded, with the first sub-layer and the second sub-layer on the basis of the interlocking structure in the sub-structure 21, thereby forming a mutually symmetrical structure of the two sub-structures 21 arranged opposite to each other in the second direction Y, so that the load is evenly distributed when bearing the load, the uniformity of the stress distribution is improved, the bonding strength that the web 100 can provide is increased, and the reliability of the web 100 is further improved.

[0068] In some optional embodiments, in the first direction X, the extension dimensions of the plurality of first extension portions 211 and the plurality of second extension portions 213 are all the same.

[0069] The first extension part 211 and the second extension part 213 in the embodiment of the present application extend to the upper and lower sides of the connection layer 212 respectively, and form an interlocking flange structure. In order to make the structural strength more uniform and stable, the plurality of first extension parts 211 and the plurality of second extension parts 213 can all have the same width. In the first direction X, they can be arranged alternately and connected one by one, thereby making the load distribution more uniform, avoiding structural weak points, and further ensuring the structural stability of the web 100.

[0070] In some optional embodiments, the web 100 also includes an end reinforcement layer 30, which is arranged between the third surface 13 and the first ply 22, and the end reinforcement layer 30 at least partially covers the third surface 13 and extends to cover at least one of the first surface 11 and the second surface 12.

[0071] In order to further improve the strength of the end of the web 100, an end reinforcement layer 30 may be provided in the web 100. The end reinforcement layer 30 may include a multi-layer stacked ply structure. The end reinforcement layer 30 may be connected to the third surface 13 and completely cover it, thereby first forming a edging structure before laying the flange structure 20, thereby making the side end surface smooth and reliable, thereby making the flange structure 20 better formed as a whole, thereby improving the structural strength that the flange structure 20 can achieve.

[0072] In some optional embodiments, the flanging structure 20 includes a plurality of first plies 22 and a plurality of second plies 23, the first plies 22 are arranged in sequence along the first direction X, and the second plies 23 are arranged in sequence along the first direction X; in a direction perpendicular to the third surface 13, the orthographic projections of the plurality of first plies 22 form a first pattern, and the first pattern covers the orthographic projection of the third surface 13.

[0073] The web 100 in the embodiment of the present application can be used to separate the blades of a generator set, and its length is relatively long, which can reach tens of meters to dozens of meters. At this time, the flange structure 20 in the web 100 can be laid in multiple sections during laying, so as to facilitate the processing of the layer material and reduce the processing error. Specifically, multiple first layers 22 and second layers 23 can be respectively arranged in contact with each other in the first direction X, and can partially overlap when in contact, until their extended size can cover the area of ​​the core material 10 where the flange structure 20 is required.

[0074] As mentioned above, in order to further improve the structural strength, the first plies 22 in the embodiment of the present application can form an interlocking structure along the first direction X above the third surface 13, that is, the first extensions 211 on both sides are arranged facing each other and staggered. On this basis, each first ply 22 is arranged to at least partially cover the third surface 13. In order to ensure the overall structural strength of the flange structure 20, the combination of the orthographic projections of each first ply 22 in the direction perpendicular to the third surface 13 can completely cover the third surface 13.

[0075] In some optional embodiments, the web 100 is symmetrically arranged relative to the first reference plane, and the first reference plane and the third surface 13 are parallel to each other.

[0076] The web 100 provided in the embodiment of the present application can be applied to the blades of a wind turbine generator set to provide structural support and anti-shearing force. When bonding the web 100 to the shell of the blade, the two opposite sides of the web 100 should be bonded simultaneously to stabilize its position. Therefore, the side surface of the web 100 opposite to the third surface 13 can also be provided with a symmetrical flange structure 20, so that the web 100 as a whole forms a symmetrical structure about the first reference plane, and the flange structures 20 on both sides are bonded respectively, thereby further improving the stability and reliability of the web 100. Optionally, the first reference surface can extend parallel to the third surface 13.

[0077] Please also read Figures 4 to 8 , Figure 4 is a flow chart of a method for manufacturing a web provided in one embodiment of the present application, Figure 5 yes Figure 4 The structural schematic diagram of step S1 in the manufacturing method shown, Figure 6 yes Figure 4 The structural schematic diagram of step S3 in the manufacturing method shown, Figure 7 yes Figure 4 The structural schematic diagram of step S4 in the manufacturing method shown, Figure 8 yes Figure 4 The structural schematic diagram of step S6 in the manufacturing method is shown.

[0078] In a second aspect, according to an embodiment of the present application, a method for manufacturing a web 100 is provided, comprising:

[0079] S1, providing a core material 10, the core material 10 extending along a first direction X and having a first surface 11, a second surface 12 arranged opposite to each other in a second direction Y, and a third surface 13 connected therebetween;

[0080] S2, providing a plurality of first layers 22, wherein the first layers 22 include a first main body portion 214 and a first extension portion 211 connected to each other;

[0081] S3, laying the first layer 22, laying the first main body 214 on the first surface 11 and the second surface 12 respectively, so that the first extension portion 211 extends along the second direction Y and at least partially covers the third surface 13 in the first direction X;

[0082] S4, disposing a connection layer 212 on the side of the first extension portion 211 away from the core material 10, so that the connection layer 212 extends along the first direction X, and in the direction perpendicular to the third surface 13, the orthographic projection of the connection layer 212 and the core material 10 are staggered and spaced apart from each other;

[0083] S5, providing a plurality of second plies 23, wherein the second plies 23 include second main body portions 215 and second extension portions 213 connected to each other;

[0084] S6, laying the second layer 23, laying the plurality of second main body portions 215 respectively on the side of the first main body portion 214 located on opposite sides of the core material 10 away from the core material 10, and setting the second extension portion 213 to cross the first extension portion 211 and cover at least part of the connection layer 212.

[0085] The embodiment of the present application also provides a method for manufacturing a web 100, which first includes step S1 of providing a core material 10, the core material 10 is the main part of the web 100, and is used to provide support, and the core material 10 is adjusted to a preset posture to prepare for subsequent laying steps. The core material 10 can be made of multiple sections spliced ​​together in its own extension direction.

[0086] In step S2 , a first ply 22 is provided. According to the length of the core material 10 , a plurality of first plies 22 may be provided. These first plies 22 may have the same shape and size and are composed of a first main body portion 214 and a first extension portion 211 that are connected to each other.

[0087] In step S3, the first ply 22 provided in the previous step is laid. Specifically, the first main body portions 214 in the plurality of first ply 22 are firstly connected to one of the first surface 11 and the second surface 12, and the connected first extension portions 211 are all located on the side close to the third surface 13. Then, the first extension portions 211 can be adjusted to extend along the second direction Y and cover at least a portion of the third surface 13, that is, the first extension portions 211 extending from the first main body portions 214 on both sides are arranged facing each other.

[0088] It can be understood that, in the first direction X, each first extension portion 211 can be arranged in sequence and staggered with each other, or one of the first extension portions 211 extending from both sides of the core material 10 can be continuously extended. No specific limitation is made here. In the embodiment where one of the first extension portions 211 extending from both sides of the core material 10 is continuously extended, the first extension portion 211 on the other side can be arranged on both sides of the continuously extended first extension portion 211 in the first direction X, and the two can be staggered with each other in this direction. Alternatively, an opening can be correspondingly provided in the continuously extended first extension portion 211, and the first extension portion 211 on the other side passes through the opening and is arranged opposite to the continuously extended first extension portion 211. This application does not make any specific limitation to this.

[0089] In step S4, a connection layer 212 is disposed on the partial area of ​​the first extension portion 211 protruding from the third surface 13 along the second direction Y. The connection layer 212 may extend along the first direction X and cover multiple first extension portions 211. Its extension dimension may be the same as or different from the extension dimension of each first ply 22. The present application does not impose any specific limitation on this. At the same time, the width of the connection layer 212 should be smaller than the width of the partial area of ​​the first extension portion 211 protruding from the third surface 13, so that there is a certain interval between its orthographic projection in the direction perpendicular to the third surface 13 and the third surface 13, so as to facilitate the subsequent arrangement of the second ply 23.

[0090] In step S5, a plurality of second plies 23 to be laid are provided, and the second plies 23 include a second main body portion 215 and a second extension portion 213 which are connected to each other, wherein the area of ​​the second main body portion 215 can be the same as or similar to the area of ​​the first main body portion 214, and the extension dimension of the second extension portion 213 should be smaller than the extension dimension of the first extension portion 211, and the same as or similar to the difference between the extension dimension of the first extension portion 211 and the extension dimension of the third surface 13 in the second direction Y, so that the sizes of the first and second extension portions after laying are adapted.

[0091] In step S6, the second ply 23 can be laid, and the second main body 215 can be laid on the side of the first main body 214 away from the core material 10, so that the two are stacked. As mentioned above, in the first direction X, the first extensions 211 can be arranged in sequence and staggered. In this embodiment, the second extension 213 passes through the gap between the connecting layer 212 and the core material 10, and is bent to the top of the connecting layer 212, so that it extends along the second direction Y. In this way, the second extension 213 can extend to the other side of the connecting layer 212 along a track that intersects with the first extension 211, so as to form a cross-interlocking structure in the flange structure 20, improve the structural strength of the web 100, and prevent cracks from expanding outward, thereby improving the bonding reliability.

[0092] As mentioned above, the first extension portion 211 in the embodiment of the present application can be continuously extended for a certain distance in the first direction X. In this embodiment, the second extension portion 213 disposed on the other side opposite to the continuously extended first extension portion 211 can pass through the opening on the first extension portion 211 to form a cross structure. Based on this, if the continuously extended first extension portion 211 is already provided with an opening for passing through the opposite first extension portion 211, the openings for passing through the opposite first extension portion 211 and the opposite second extension portion 213 should be arranged at intervals from each other to avoid the problem of the structural strength of the continuously extended first extension portion 211 being reduced or even being cut off at the opening.

[0093] See also Fig. 9 , Fig. 9 is a flow chart of a method for manufacturing a web provided by another embodiment of the present application. In some optional embodiments, step S3 of laying the first ply 22 further includes:

[0094] S31 , adjusting the location of the first extension portions 211 so that adjacent first extension portions 211 are connected to the first main body portions 214 disposed on the first surface 11 and the second surface 12 in the first direction X.

[0095] In step S3, the first ply 22 provided in the previous step needs to be laid onto the core material 10. During the laying, the positions of the first ply 22 located on both sides of the core material 10 can be adjusted so that the adjacent first extension portions 211 are respectively connected to the first main body portions 214 located on different surfaces to form a second cross-interlocking structure in the first direction X, thereby further improving the strength of the flanging structure 20.

[0096] In some optional embodiments, the step S1 of providing the core material and the step S2 of providing the plurality of first plies further include:

[0097] S11 , providing an end reinforcement layer 30 , laying the end reinforcement layer 30 on the third surface 13 , and making the end reinforcement layer 30 at least partially cover at least one of the first surface 11 and the second surface 12 .

[0098] The web 100 in the embodiment of the present application may also be provided with an end reinforcement layer 30 for further strengthening the end, and the layer structure may be directly stacked with the third surface 13. Correspondingly, between the step S1 of providing the core material 10 and the step S2 of providing the first ply, a step S11 of laying the end reinforcement layer 30 may be included. Similar to the first ply 22 and the second ply 23, the end reinforcement layer 30 may also be a biaxial cloth, and the end reinforcement layer 30 may include a multi-layer structure so that it covers the third surface 13 at the same time, so as to further strengthen the structural strength of the connection between the flange structure 20 and the core material 10.

[0099] It can be understood that when laying the end reinforcement layer 30, the multi-layer structure included therein can be laid layer by layer, and the setting position of each layer structure can have a certain staggered area. It only needs to cover the third surface 13 and extend to both sides to cover the end of the third surface 13 of the core material 10. The present application does not make any specific limitation on this.

[0100] In some optional embodiments, the step S1 of providing a core material further includes:

[0101] S12, providing a mold, and placing the core material 10 in the mold;

[0102] After the step S6 of laying the second layer, the method further includes:

[0103] S7. Pour filler into the mold and solidify it to obtain a web.

[0104] The web 100 in the embodiment of the present application may also use a corresponding mold during the manufacturing process. Specifically, the step S1 of providing the core material 10 may also include a step S11 of placing the core material 10 in a mold, which matches the shape of the web 100 to be formed and can be used for resin infusion.

[0105] Furthermore, after the core material 10 is placed in the mold, the first layer 22 and the second layer 23 can be laid step by step in the mold. After the laying process of the second layer 23 is completed in step S6, the preparation part composed of the core material 10 and each layer in the mold can be evacuated and filled with fillers. After the fillers are solidified and cooled, they can be polished and tested to become a usable web 100. For example, the fillers can be made of resin materials.

[0106] In a third aspect, a blade is proposed according to an embodiment of the present application, comprising the web in any embodiment of the first aspect.

[0107] The embodiment of the present application also provides a blade, in which at least one web 100 in any embodiment of the first aspect is provided, the extension direction of the web 100 is the same as the extension direction of the blade as a whole, and the surface of the flange structure 20 facing away from the core material 10 is in contact with the inner surface of the web shell to provide good support from the inside. When multiple webs 100 are provided in the blade at the same time, the shape and size of these webs 100 can be adjusted according to the shape and size of the blade, and these webs 100 can extend in parallel and be spaced apart from each other.

[0108] See also Fig.10 , Fig.10 Schematic diagram of the structure of a separate generator set provided by an embodiment of the present application. In a fourth aspect, according to an embodiment of the present application, a wind turbine generator set 200 is provided, comprising the blades in any embodiment of the third aspect.

[0109] The blade and wind turbine generator set 200 provided in the embodiment of the present application have all the beneficial effects of the web 100 provided in the embodiment of the present application. For details, please refer to the specific description of the web 100 in the above embodiments, which will not be repeated in this embodiment.

[0110] Although the present application has been described with reference to preferred embodiments, various modifications may be made thereto and parts thereof may be replaced with equivalents without departing from the scope of the present application. In particular, the various technical features mentioned in the various embodiments may be combined in any manner as long as there are no structural conflicts. The present application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A web, characterized in that: include: A core material extending along a first direction, the core material having a first surface, a second surface and a third surface connected therebetween which are arranged opposite to each other in a second direction, the first direction intersecting the second direction; A flanging structure is arranged at one end portion of the third surface and extends to both sides along the second direction. The flanging structure includes a plurality of substructures respectively arranged on the first surface and the second surface away from each other. Each of the substructures includes a first extension portion, a second extension portion, and a connecting layer sandwiched therebetween and extending along the first direction. In the first direction, the orthographic projection of the first extension portion and the orthographic projection of the second extension portion at least partially intersect with each other.

2. The web according to claim 1, characterized in that In the first direction, the first extension portions and the second extension portions are arranged alternately, and an orthographic projection of the first extension portion and an orthographic projection of the second extension portion intersect to form an intersection point, and the intersection point is located between the connection layer and the core material.

3. The web according to claim 1, characterized in that The flange structure further includes a first main body portion and a second main body portion, wherein the first main body portion and the first extension portion are connected to each other to form a first layer, and the second main body portion and the second extension portion are connected to each other to form a second layer; The first surface and the second surface are both sequentially stacked with the first main body portion and the second main body portion.

4. The web according to claim 3, characterized in that Each of the first plies includes a plurality of the first extensions, and each of the second plies includes a plurality of the second extensions. The plurality of the first extensions and the plurality of the second extensions are arranged at intervals along the first direction.

5. The web according to claim 3, characterized in that The first ply includes a first sub-ply disposed on the first surface and a second sub-ply disposed on the second surface. In the first direction, the first extension portion in the first sub-ply and the first extension portion in the second sub-ply are staggered and alternately disposed.

6. The web according to claim 3, characterized in that The flange structure includes a plurality of the first layers and a plurality of the second layers, wherein the first layers are sequentially connected and arranged along the first direction, and the second layers are sequentially connected and arranged along the first direction; In a direction perpendicular to the third surface, orthographic projections of the plurality of first plies form a first pattern, and the first pattern covers the orthographic projection of the third surface.

7. The web according to claim 1, characterized in that In the first direction, extension dimensions of the first extension portions and the second extension portions are all the same.

8. The web according to claim 1, characterized in that The web further includes an end reinforcement layer, which is disposed between the third surface and the first extension portion. The end reinforcement layer at least partially covers the third surface and extends to cover at least one of the first surface and the second surface.

9. The web according to any one of claims 1 to 8, characterized in that The web is symmetrically arranged relative to the first reference surface, and the first reference surface is parallel to the third surface.

10. A method for manufacturing a web, characterized in that: include: Providing a core material, the core material extending along a first direction and having a first surface, a second surface and a third surface connected therebetween, which are oppositely arranged in a second direction; Providing a plurality of first plies, the first plies comprising a first main body portion and a first extension portion connected to each other; Laying the first layer, laying the first main body on the first surface and the second surface respectively, so that the first extension portion extends along the second direction and at least partially covers the third surface; A connecting layer is arranged on a side of the first extension portion away from the core material, so that the connecting layer extends along the first direction, and in a direction perpendicular to the third surface, an orthographic projection of the connecting layer and the core material are staggered and arranged at intervals; providing a plurality of second plies, the second plies comprising second main body portions and second extension portions connected to each other; Lay the second layer, lay a plurality of the second main bodies respectively on the side of the first main body located on opposite sides of the core material away from the core material, and cross the second extension part with the first extension part and cover at least part of the connection layer.

11. The manufacturing method according to claim 10, characterized in that: The step of laying the first layer further comprises: The setting positions of the first extension parts are adjusted so that the adjacent first extension parts are connected to the first main body parts respectively arranged on the first surface and the second surface in the first direction.

12. The manufacturing method according to claim 10, characterized in that: The step of providing a core material and the step of providing a plurality of first layers further include: An end reinforcement layer is provided and laid on the third surface, so that the end reinforcement layer at least partially covers at least one of the first surface and the second surface.

13. The manufacturing method according to claim 10, characterized in that: The step of providing the core material also includes: Providing a mold, and placing the core material in the mold; After the step of laying the second layer, the step further includes: A filler is poured into the mold and solidified to obtain the web.

14. A blade, characterized in that: The invention comprises a web as claimed in any one of claims 1 to 9.

15. A wind turbine generator set, characterized in that: Comprising a blade as claimed in claim 14.

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