Foam metal wind power blade and preparation method thereof

Abstract

A foam metal wind power blade and a preparation method thereof belong to the technical field of small wind power generation equipment, a small wind power generator blade is manufactured by utilizing the characteristics of foam metal, and a main body comprises a foam metal blade layer, and an adhesive layer and a reinforcing layer on the back of the foam metal blade layer. A foam metal material forms a required foam metal blade layer shape through cutting, grinding, bending, bonding and other processing modes, the back surface is coated to form an adhesive layer, and a reinforcing material is tightly attached to the adhesive applying surface to form a reinforcing layer. The wind power blade has the beneficial effects that the manufacturing process links of the wind power blade are reduced, the overall weight is reduced, the cost is reduced, wind power retention is increased due to the holes, a large amount of fine vortexes are increased to form thrust, and the smooth surface of the enhancement layer is utilized on the back surface, so that the starting wind speed of the blade is reduced, and the rotating power generation efficiency is improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of small wind power generation equipment, and in particular relates to a foam metal wind power blade and a preparation method thereof. Background Art

[0002] The blades of small wind turbines are the main components for obtaining wind energy. Whether it is a horizontal axis wind turbine blade or a vertical axis wind turbine blade, the preparation method is to first make a blade prototype and then make a blade mold, and manually lay fiberglass fiber reinforcement materials in the mold, vacuum introduce polyester (epoxy, vinyl), phenolic resin and other bonding, and fill it with balsa wood or low-density foam core materials as the main form. Since balsa wood or foam resin itself has no strength, it is only used as an internal filler for the blade. The weight of the fiberglass or metal skin of the entire blade and the wind load during work require more metal or composite fiber tube skeletons to support it internally, which not only makes the process cumbersome but also makes the wind wheel blades too heavy and requires a higher starting wind speed. However, if aluminum alloy plates are used as some vertical axis resistance type wind turbine blades, the plates are too thin to bear the load capacity and rigidity, while thickening the plates will lead to excessive weight and a corresponding increase in starting torque.

[0003] Moreover, existing blades do not distinguish the difference in surface roughness between the windward side and the leeward side, and do not maximize the use of the wind energy impact when the wind contacts different rough surfaces, thereby improving the wind energy utilization rate of the blades. For example, if the windward side of the blade is rough, it can increase wind resistance and increase driving force, while if the leeward side of the blade is smooth, it can reduce wind resistance and reduce consumption during rotation, especially for the Savonius fan, the increase and decrease of the blade during rotation improves the efficiency of the fan.

[0004] In addition, as an existing foam metal, it refers to a metal material with a certain number of pores, a certain pore size, and a certain porosity in a metal matrix. The pore size is 0.5-6mm and the porosity is greater than 90%. It is called foam metal. Currently used in battery electrodes, catalytic carriers, noise reduction, sound insulation and shock absorption, foam metal not only has high specific stiffness, easy reprocessing, but also has the wind resistance characteristics of pores. So far, its characteristics have not been used in the field of wind turbine blades. Summary of the invention

[0005] In order to overcome the deficiencies of the prior art, the present invention provides a foam metal wind turbine blade and a preparation method thereof, which utilizes the characteristics of foam metal to manufacture small wind turbine blades while maintaining the characteristics of light weight and high strength of the material.

[0006] The present invention is implemented in this way: a foam metal wind turbine blade, which is characterized by comprising a three-layer structure, a main body being a foam metal blade layer, and an adhesive layer and a reinforcement layer on the back thereof.

[0007] The foam metal blade layer is foam aluminum, foam copper, foam nickel or other foam metal materials; the reinforcement layer is one or a combination of metal sheets and composite fiber reinforcement materials; the metal sheet is one of aluminum alloy, stainless steel or other metal materials; the composite fiber reinforcement material is a matrix resin and reinforcing fiber; the reinforcing fiber is one or more of carbon fiber, glass fiber, aramid fiber or other fibers; the matrix resin is a thermosetting resin or a blended modified system thereof with an elastomeric resin; the thermosetting resin is one or more of unsaturated polyester resin, epoxy resin, phenolic resin, silicone resin, polyimide resin or other resins; the elastomeric resin is one or more of styrene elastomer, olefin elastomer, polyurethane elastomer or other elastomeric materials; the adhesive layer is a matrix resin.

[0008] The method for preparing a foam metal wind turbine blade is characterized in that: first, the foam metal material is processed by cutting, grinding, bending, bonding and other processing methods to form the desired foam metal blade layer shape, and after forming, the back side of the foam metal blade layer (the leeward side in the working state) is coated with a matrix resin to form an adhesive layer, and the reinforcing material is tightly attached to the adhesive surface to form a reinforcement layer; when the reinforcement layer is in the form of a metal sheet, the sheet cut to a corresponding size is attached and bonded to the main blade adhesive layer; when the reinforcement layer is in the form of a composite fiber reinforced material, the following steps are taken: the matrix resin is coated on the back side (leeward side) of the foam metal blade layer, and the foam holes on the surface are filled to form an adhesive layer, and then the fiber reinforcement material is laid, so that the base resin and the fiber material are repeatedly stacked until the desired thickness is formed; after the molding is completed, conventional curing or heating and pressurizing curing is adopted depending on the curing conditions of the matrix resin.

[0009] The beneficial effects of the present invention are as follows: utilizing the characteristics of light weight, holes, appropriate strength and easy processing of foam metal, so that the blades have the functions of both forming and skeleton, which greatly reduces the steps in the production process of wind turbine blades, reduces the weight of peripheral pipe supports and skins, and reduces the production, transportation and installation costs; at the same time, the front side (the windward side in the working state) of the wind turbine blade made of foam metal is covered with holes to increase wind retention and increase a large number of small eddies to form thrust, while the back side utilizes the smooth surface of the reinforcement layer, thereby reducing the starting wind speed of the blades and improving the efficiency of rotational power generation. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The invention will be further described below in conjunction with the accompanying drawings.

[0011] Figure 1 This is a schematic diagram of the structure of a foam metal wind turbine blade of the present invention; In the figure: 1. Foam metal blade layer; 2. Adhesive layer; 3. Reinforcement layer. DETAILED DESCRIPTION

[0012] The present invention will be further described below in conjunction with the accompanying drawings and specific implementation methods.

[0013] This embodiment is a foam metal wind turbine blade, which is characterized by: comprising a three-layer structure, the main body is a foam metal blade layer 1, and the adhesive layer 2 and the reinforcement layer 3 on the back thereof. The foam metal blade layer 1 is foam aluminum, foam copper or other foam metal materials; the reinforcement layer 3 is one or a combination of metal sheets and composite fiber reinforcement materials; the metal sheet is one of aluminum alloy, stainless steel or other metal materials; the composite fiber reinforcement material is a matrix resin and reinforcement fiber; the reinforcement fiber is one or more of carbon fiber, glass fiber, aramid fiber or other fibers; the matrix resin is a thermosetting resin or a blended modified system thereof with an elastomer resin; the thermosetting resin is one or more of unsaturated polyester resin, epoxy resin, phenolic resin, silicone resin, polyimide resin or other resins; the elastomer resin is one or more of styrene elastomer, olefin elastomer, polyurethane elastomer or other elastomer materials; the adhesive layer 2 is one of the matrix resins.

[0014] The method for preparing a foam metal wind turbine blade is characterized in that: first, the foam metal material is formed into the desired foam metal blade layer 1 shape by cutting, grinding, bending, bonding and other processing methods; after forming, the back side of the foam metal blade layer 1 (the leeward side in the working state) is coated with a matrix resin to form an adhesive layer 2, and the reinforcing material is tightly attached to the adhesive surface to form a reinforcing layer 3; when the reinforcing layer 3 is a metal sheet, the sheet cut to a corresponding size is attached and bonded to the main blade adhesive layer 2; when the reinforcing layer 3 is a composite fiber reinforced material, the following steps are taken: the matrix resin is coated on the back side of the foam metal blade layer 1, and the foam holes on the surface are filled to form an adhesive layer 2, and then the fiber reinforcement material is laid, so that the base resin and the fiber reinforcement material are repeatedly stacked until the desired thickness is formed; after the forming is completed, conventional curing or heating and pressurizing curing is adopted depending on the curing conditions of the matrix resin.

[0015] The following examples are only used to illustrate the preparation process of the foam metal wind turbine blade of the present invention, and are not used to limit the scope of the present invention.

[0016] Embodiment 1: The foam aluminum is made into small horizontal axis wind turbine propeller blades with varying step sizes through cutting, grinding and other processing methods. The aluminum alloy sheet is cut and trimmed according to the contour size of the back of the blade and bonded to the gluing surface of the blade; the front side of the blade (the windward side in the working state) keeps the foam metal in its original state, and the leeward side of the blade is coated with polyurethane modified unsaturated polyester resin glue, and the resin glue is allowed to fill the foam pores. Then, the aluminum alloy sheet is attached to the coated surface of the blade, and the edges are aligned and bonded to complete the overall production of the foam metal wind turbine blade.

[0017] Embodiment 2: Cut and bend the copper foam sheet to form the shape of an arc-shaped blade for a vertical axis fan, apply phenolic resin glue on the back side of the arc-shaped blade, i.e., the convex side, and after sufficient glue application, apply fiber fabric to the glue surface, and use a rolling tool to eliminate residual air and compact it tightly, then repeatedly apply glue and lay fiber fabric at a 45-degree angle and roll it until a reinforcement layer of the required thickness is formed, and transport the finished product into an autoclave, heat and pressurize it to cure it according to the resin specification requirements.

[0018] Although the above describes the specific implementation of the present invention, it is not intended to limit the scope of protection of the invention. Modifications or variations that can be made by technicians in the relevant field without creative work on the basis of the technical solution of the present invention are still within the scope of protection of the present invention.

Claims

1. A foam metal wind turbine blade, characterized by: It comprises a three-layer structure, the main body of which is a foam metal blade layer (1), and an adhesive layer (2) and a reinforcement layer (3) on the back side thereof.

2. The foam metal wind turbine blade according to claim 1, characterized in that: The foam metal blade layer (1) is foam aluminum, foam copper or other foam metal materials; the reinforcement layer (3) is one or a combination of metal sheets and composite fiber reinforcement materials; the metal sheet is aluminum alloy, stainless steel or other metal materials; the composite fiber reinforcement material is a matrix resin and reinforcing fiber; the reinforcing fiber is one or more of carbon fiber, glass fiber, aramid fiber or other fibers; the matrix resin is a thermosetting resin or a blended modified system thereof with an elastomeric resin; the thermosetting resin is one or more of unsaturated polyester resin, epoxy resin, phenolic resin, silicone resin, polyimide resin or other resins; the elastomeric resin is one or more of styrene elastomer, olefin elastomer, polyurethane elastomer or other elastomeric materials; the adhesive layer (2) is a matrix resin.

3. A method for preparing a foam metal wind turbine blade according to claim 1-2, characterized in that: First, the foam metal material is processed by cutting, grinding, bending, bonding and other processing methods to form the desired foam metal blade layer (1) shape. After forming, the back side (leeward side in the working state) of the foam metal blade layer (1) is coated with a base resin to form an adhesive layer (2), and the reinforcing material is tightly attached to the adhesive surface to form a reinforcing layer (3); when the reinforcing layer (3) is a metal sheet, the sheet cut to a corresponding size is attached and bonded to the main blade adhesive layer (2); when the reinforcing layer (3) is a composite fiber reinforced material, the following steps are taken: the base resin is coated on the back side of the foam metal blade layer (1) and the foam holes on the surface are filled to form an adhesive layer (2), and then the fiber reinforcement material is laid, so that the base resin and the fiber material are repeatedly stacked until the desired thickness is formed; after the forming is completed, conventional curing or heating and pressure curing is adopted depending on the curing conditions of the base resin.

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