Ultra-long carbon fiber blade and manufacturing method thereof

Abstract

The invention discloses a super-long carbon fiber blade and a manufacturing method thereof. The super-long carbon fiber blade comprises a blade body, a carbon fiber layer and a carbon fiber layer, the first end of the connecting body is connected with the blade body into a whole in an inserted mode; the blade tip comprises a first blade tip shell, a second blade tip shell and a blade tip main beam, the blade tip main beam is formed by sequentially connecting a plurality of sub-beams end to end in an inserted mode, and the head end of the first sub-beam and the second end of the connecting body are connected into a whole in an inserted mode; the first blade tip shell and the second blade tip shell are buckled to wrap the periphery of the blade tip main beam, and gaps between the first blade tip shell and the blade body and between the second blade tip shell and the blade body are sealed through sealing adhesive tape. The ultra-long carbon fiber blade is not limited by the plant capacity in the production process, and is convenient to transport and low in transportation cost.

Description

Technical Field

[0001] The present invention relates to the technical field of wind wheel blade manufacturing, and more specifically, to an ultra-long carbon fiber blade and a manufacturing method thereof. Background Art

[0002] The rotor blade is a key component of wind turbines to capture wind energy and determines the capacity of wind turbines. In recent years, the capacity of onshore wind turbines has exceeded 10MW, and offshore wind turbines above 15MW have been put into operation in batches. Traditional pure glass fiber blades cannot meet the requirements of power generation. Therefore, the application of carbon fiber blades has increased year by year.

[0003] Carbon fiber blades are mainly made of pultruded plates as the main beam of the blade. The carbon fiber pultruded plate main beam has a higher strength-to-mass ratio due to its higher specific elastic modulus, so it is an inevitable choice for designing and manufacturing ultra-long flexible blades. However, ultra-long carbon fiber blades may not be able to be unfolded during production due to the limitation of plant capacity, and the transportation of ultra-long carbon fiber blades is limited, resulting in increased transportation costs.

[0004] In summary, how to solve the problem that the production of ultra-long carbon fiber blades is limited by the capacity of the plant and the transportation cost of the ultra-long carbon fiber blades is high is an urgent problem to be solved by technical personnel in this field. Summary of the invention

[0005] In view of this, an object of the present invention is to provide an ultra-long carbon fiber blade, which is not limited by the capacity of the plant during production and is convenient to transport with low transportation cost.

[0006] Another object of the present invention is to provide a method for manufacturing an ultra-long carbon fiber blade for manufacturing the above-mentioned ultra-long carbon fiber blade.

[0007] In order to achieve the above object, the present invention provides the following technical solutions:

[0008] An ultra-long carbon fiber blade, comprising:

[0009] leaf body;

[0010] A connector, a first end of which is plug-connected to the blade body as a whole;

[0011] The blade tip comprises a first blade tip shell, a second blade tip shell and a blade tip main beam, wherein the blade tip main beam is formed by connecting a plurality of sub-beams end to end in sequence, and the head end of the first sub-beam is connected to the second end of the connector as a whole by plugging, the first blade tip shell and the second blade tip shell are buckled and wrapped around the outer periphery of the blade tip main beam, and the gap between the two and the blade body is sealed by sealing tape.

[0012] Preferably, each section of the sub-beam is a hollow tube structure, and the diameter of the blade tip main beam gradually decreases from its head end to its tail end.

[0013] Preferably, the connector is a hollow tube structure, and the diameter of the second end of the connector is larger than the diameter of the first end of the sub-beam of the first section.

[0014] Preferably, an elastic buckle is provided on the outer wall of the head end of one section of the sub-beam, and a slot is provided on the inner wall of the tail end of another section of the sub-beam adjacent to the head end of one section of the sub-beam, and the slot is snap-fitted with the elastic buckle.

[0015] Preferably, the insertion joints of two adjacent sub-beams are fixedly connected by gluing.

[0016] Preferably, the front end and the rear end of each segment of the sub-beam are both chamfered.

[0017] Preferably, the blade body includes a blade body shell and two blade body main beams, the two blade body main beams are relatively arranged in the blade body shell and are integrally cast therewith, and a gap is reserved between the two blade body main beams for the first end of the connector to be inserted, the first end of the connector is integrally cast with the blade body main beam and the blade body shell, or the first end of the connector is fixedly connected to the blade body main beam by gluing.

[0018] Preferably, each section of the sub-beam is a carbon fiber pultruded profile; the blade main beam is a carbon fiber pultruded profile or a glass fiber pultruded profile.

[0019] A method for manufacturing an ultra-long carbon fiber blade, used to manufacture any of the ultra-long carbon fiber blades described above, comprising:

[0020] The blade body and the connecting body are prefabricated in the factory using the blade body mold;

[0021] Prefabricating a first blade tip shell and a second blade tip shell respectively using a blade tip shell mold in a factory;

[0022] Multiple sections of beams are processed in the workshop;

[0023] Transporting the blade body and the connecting body integrally connected therewith, the first blade tip shell, the second blade tip shell and the plurality of sections of the sub-beams to an installation site;

[0024] Insert the head end of the first segment of the sub-beam into the connector, then insert the head and tail of the remaining sub-beams to form a blade tip main beam, and glue the insertion points of the sub-beams of each segment to fix them;

[0025] Applying glue on the first blade tip shell and the second blade tip shell, and then buckling and wrapping the first blade tip shell and the second blade tip shell around the outer periphery of the blade tip main beam;

[0026] Glass fiber cloth is hand-laid at the gaps between the first blade tip shell, the second blade tip shell and the blade body, and then the glass fiber cloth is cured to complete the on-site installation.

[0027] Preferably, the step of prefabricating the blade body and the connecting body connected as one body by using the blade body mold in the factory specifically includes:

[0028] Injection molding the blade body main beam and the blade body shell into a single piece on the blade body mold;

[0029] Processing the connector;

[0030] Glue is applied to one end of the connector, and then the one end of the connector is inserted into the blade body shell.

[0031] In the production of an ultra-long carbon fiber blade provided by the present invention, a blade body and a connector connected as a whole, as well as a first blade tip shell and a second blade tip shell can be prefabricated first. Since the blade tip main beam is formed by plugging multiple sections of sub-beams end to end, multiple sections of sub-beams can be prefabricated first. Thus, various components that can be assembled together into an ultra-long carbon fiber blade are prefabricated in the factory, and then the various components are transported to the site, that is, the split transportation of the ultra-long carbon fiber blade is realized. After arriving at the site, the head end of the first section of the sub-beam is plugged into the connector, and then the remaining sub-beams are plugged end to end to form the blade tip main beam, and then the first blade tip shell and the second blade tip shell are buckled and wrapped around the outer periphery of the blade tip main beam, and finally the gap between the first blade tip shell and the second blade tip shell and the blade body is sealed by sealing tape, and the on-site installation of the ultra-long carbon fiber blade can be completed.

[0032] In summary, the present invention can prefabricate various components that can be assembled together to form ultra-long carbon fiber blades during factory production. After being transported to the installation site, the various components can be conveniently assembled into ultra-long carbon fiber blades. Therefore, the ultra-long carbon fiber blades are not limited by the capacity of the factory during production, and are convenient to transport with low transportation costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.

[0034] Figure 1 A schematic diagram of the structure of an ultra-long carbon fiber blade provided by the present invention;

[0035] Figure 2 for Figure 1A partial exploded view of the middle lobe tip;

[0036] Figure 3 This is a schematic diagram of the structure of the blade tip main beam provided by the present invention;

[0037] Figure 4 This is a schematic diagram of the disassembly and assembly of the blade body and the connector provided by the present invention.

[0038] Reference numerals:

[0039] 1- blade body; 11- blade body shell; 12- blade body main beam;

[0040] 2-connector;

[0041] 3-blade tip; 31-first blade tip shell; 32-second blade tip shell; 33-blade tip main beam; 331-sub-beam. DETAILED DESCRIPTION

[0042] 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.

[0043] The core of the present invention is to provide an ultra-long carbon fiber blade, which is not limited by the capacity of the plant during production and is convenient to transport with low transportation cost.

[0044] Another core of the present invention is to provide a method for manufacturing the ultra-long carbon fiber blades mentioned above.

[0045] It should be noted that, in this specification, relational terms such as first and second are merely used to distinguish one entity from other entities, but do not necessarily require or imply any actual relationship or order between these entities.

[0046] Please refer to Figure 1 and Figure 2 The present invention provides an ultra-long carbon fiber blade, comprising a blade body 1, a connector 2 and a blade tip 3.

[0047] The blade body 1 is the main part of the blade, generally presenting a curved shape, and the end of the blade body 1 is connected to the blade tip 3. For the ultra-long carbon fiber blade, the blade is divided into two components, namely the blade body 1 and the blade tip 3, which are processed separately and then assembled to facilitate the production and transportation of the blade. It should be noted that the blade body 1 is generally composed of a blade body shell 11 and a blade body main beam 12 wrapped therein, wherein the blade body main beam 12 is the main load-bearing structure of the blade body 1, which is used to ensure the stable operation of the blade body 1.

[0048] The first end of the connector 2 is plug-connected to the blade body 1 as a whole.

[0049] Among them, after the first end of the connector 2 is inserted into the blade shell 11, the first end of the connector 2 can be connected to either or both of the blade shell 11 and the blade main beam 12 by gluing. In addition, the first end of the connector 2 can also be integrally cast with the blade shell 11 and the blade main beam 12.

[0050] The blade tip 3 includes a first blade tip shell 31, a second blade tip shell 32 and a blade tip main beam 33. The blade tip main beam 33 is formed by plugging multiple sections of sub-beams 331 end to end in sequence, and the head end of the first section of the sub-beam 331 is plugged and connected to the second end of the connector 2 as a whole. The first blade tip shell 31 and the second blade tip shell 32 are buckled and wrapped around the outer periphery of the blade tip main beam 33, and the gap between the two and the blade body 1 is sealed by a sealing tape. Preferably, the sealing tape can be made of glass fiber cloth with good insulation, good heat resistance and good corrosion resistance.

[0051] It should be noted that for the ultra-long carbon fiber blades, the blade tip 3 also has a longer length. The blade tip 3 is further divided into a first blade tip shell 31, a second blade tip shell 32, and a blade tip main beam 33 with multiple segmented beams 331 connected end to end, and other components are processed separately and then assembled, which can further facilitate the production and transportation of the blades.

[0052] Therefore, the present invention can prefabricate various components that can be assembled together to form ultra-long carbon fiber blades in factory production. After being transported to the installation site, the various components can be conveniently assembled into ultra-long carbon fiber blades. Therefore, the ultra-long carbon fiber blades are not limited by the capacity of the factory during production, and are convenient to transport with low transportation costs.

[0053] Regarding the specific structure of the sub-beam 331, based on the above embodiment, please refer to Figure 3 Each segment beam 331 is a hollow tube structure, and the diameter of the blade tip main beam 33 gradually decreases from the head end to the tail end.

[0054] Specifically, each segment beam 331 adopts a hollow tube structure, which is not only convenient for the head-to-tail connection of multiple segment beams 331 to improve the installation efficiency, but also can greatly reduce the weight of the blade tip 3, that is, significantly reduce the weight of the blade. In addition, the diameter of each segment beam 331 is gradually reduced from its head end to its tail end, and the head end diameter of a segment beam 331 is smaller than the tail end diameter of another segment beam 331 adjacent to it. On the one hand, it not only ensures the connection of two adjacent segment beams 331, but also makes the overall blade tip main beam 33 gradually reduce in diameter from its head end to its tail end, which can make the blade tip 3 shell wrapped around the outer periphery of the blade tip main beam 33 gradually reduce, so that the blade tip 3 gradually becomes thinner, which can reduce the air resistance of the airflow at the end of the blade, thereby improving the wind energy conversion efficiency and reducing energy consumption.

[0055] Regarding the specific structure of the connector 2, based on the above embodiment, please refer to Figure 2 and Figure 4 The connecting body 2 is a hollow tube structure, and the diameter of the second end of the connecting body 2 is larger than the diameter of the first end of the first section beam 331.

[0056] Specifically, the connector 2 adopts a hollow tube structure, which is not only convenient for plugging the sub-beam 331, but also can further reduce the weight of the blade. In addition, the second end diameter of the connector 2 is larger than the first end diameter of the first sub-beam 331 to ensure that the first section of the first sub-beam 331 is inserted into the connector 2.

[0057] Optionally, the sub-beam 331 and the connector 2 may be rectangular tubes with rectangular cross-sections, which have the characteristics of good structural stability, strong bearing capacity and convenient connection. Of course, the sub-beam 331 and the connector 2 may also be circular tubes with circular cross-sections, and the structural shapes are not unique. It should be noted that the shapes of the sub-beam 331 and the connector 2 should be plug-fitted.

[0058] Regarding the material of the sub-beam 331, based on the above embodiment, each sub-beam 331 is a carbon fiber pultruded profile. Since the carbon fiber pultruded profile has the characteristics of light weight, extremely high strength and modulus, it can greatly enhance the bearing capacity of the blade tip main beam 33 to lighten the blade tip main beam 33, thereby making the blade tip 3 structure light and stable.

[0059] Regarding the specific plug-in method of two adjacent sub-beams 331, in one embodiment, an elastic buckle is provided on the outer wall of the head end of one sub-beam 331, and a slot is provided on the inner wall of the tail end of another sub-beam 331 adjacent to the head end of one sub-beam 331, and the slot is adapted to be snap-fitted with the elastic buckle.

[0060] Specifically, at least one buckle is provided on the outer wall of the head end of a segment beam 331, and the buckle is elastic, so as to facilitate the insertion of the segment beam 331 into another segment beam 331 in front of it. Preferably, two elastic buckles are provided and are symmetrically placed on the two outer side walls of the segment beam 331 with the axis of the segment beam 331 as the center line. A slot corresponding to the elastic buckle is provided on the inner wall of the tail end of the other segment beam 331 in front of the segment beam 331.

[0061] Therefore, the two adjacent sections of the beam 331 are connected by elastic buckles and slots, which not only ensures a firm and reliable connection and is not easy to loosen, but also facilitates disassembly and assembly, greatly improving the efficiency of disassembly and assembly of the blade tip main beam 33, and thus helps to improve the efficiency of on-site installation of the blade.

[0062] In another embodiment, the insertion places of two adjacent sub-beams 331 are fixedly connected by gluing. It is understandable that the gluing and fixing connection can save the processing cost and time of the sub-beams 331 and also ensure a firm connection.

[0063] In order to further optimize the plug-in method of two adjacent sections of sub-beams 331, on the basis of the above embodiment, the head port and the tail port of each section of sub-beam 331 are provided with chamfers to eliminate the steps at the ports of the sub-beam 331, making it more convenient to plug-in two adjacent sections of sub-beams 331 and having better conformability.

[0064] Regarding the specific structure of the blade body 1, based on the above embodiment, please refer to Figure 1 , Figure 2 and Figure 4 The blade body 1 includes a blade body shell 11 and two blade body main beams 12. The two blade body main beams 12 are arranged in the blade body shell 11 and are integrally cast therewith, and a gap is left between the two blade body main beams 12 for the first end of the connector 2 to be inserted. Therefore, the two blade body main beams 12 are arranged in this way, which can enhance the structural stability of the blade body 1 and improve the convenience of plugging the connector 2.

[0065] In addition, the first end of the connector 2 is integrally cast with the blade main beam 12 and the blade shell 11, or the first end of the connector 2 is fixedly connected to the blade main beam 12 by gluing, as long as the conditions for connecting the blade 1 and the connector 2 as a whole are met.

[0066] Regarding the material of the blade main beam 12 , since the blade 1 is thicker than the blade tip 3 , the blade main beam 12 used to support the blade 1 can be made of a carbon fiber pultruded profile or a glass fiber pultruded profile, both of which have the characteristics of light weight and high strength.

[0067] The present invention also provides a method for manufacturing an ultra-long carbon fiber blade, which is used to manufacture the ultra-long carbon fiber blade disclosed in the above embodiment, comprising:

[0068] Step 1, prefabricate the blade body 1 and the connecting body 2 connected as one in a factory using a blade body 1 mold;

[0069] Step 2, prefabricating the first blade tip shell 31 and the second blade tip shell 32 in the workshop using the blade tip 3 shell mold;

[0070] Step 3, processing multiple sections of beams 331 in the workshop;

[0071] Step 4, transporting the blade body 1 and the connecting body 2 integrally connected therewith, the first blade tip shell 31, the second blade tip shell 32 and the multi-segment beam 331 to the installation site;

[0072] Step 5, insert the head end of the first segment of the sub-beam 331 into the connector 2, then plug the remaining segment of the sub-beam 331 end to end to form the blade tip main beam 33, and glue the plug-in parts of each segment of the sub-beam 331 to fix them;

[0073] Step 6, applying glue on the first blade tip shell 31 and the second blade tip shell 32, and then buckling and wrapping the first blade tip shell 31 and the second blade tip shell 32 around the outer periphery of the blade tip main beam 33;

[0074] Step 7, hand-laying glass fiber cloth in the gaps between the first blade tip shell 31, the second blade tip shell 32 and the blade body 1, and then curing the glass fiber cloth to complete the on-site installation.

[0075] It should be noted that the first blade tip shell 31 and the second blade tip shell 32 can be buckled together to form a closed blade tip 3 shell, which has a gap only between the blade tip 3 shell and the blade body 1, and glass fiber cloth is hand-pasted at the gap. After the surface of the glass fiber cloth is cured, the epoxy resin can penetrate into the glass fiber to enhance its adhesion to effectively seal the gap, thereby ensuring the internal sealing of the blade. On the one hand, it can prevent moisture, dust and other impurities from entering the interior of the blade to protect the performance stability of the blade; on the other hand, it can reduce wind resistance and noise, and improve the efficiency and quality of wind power generation.

[0076] In the above step 1, it specifically includes:

[0077] Step 11, integrally pouring and molding the blade body main beam 12 and the blade body shell 11 on the blade body 1 mold;

[0078] Step 12, processing the connector 2;

[0079] Step 13: apply glue to one end of the connector 2 , and then insert the one end of the connector 2 into the blade body shell 11 .

[0080] It should be noted that the connector 2 can adopt a hollow tube structure, which is simple to manufacture. After the blade main beam 12 and the blade shell 11 are integrally cast in the blade 1 mold, the connector 2 is inserted into the blade shell 11 and glued to the blade main beam 12. This method, compared with the integral casting of the blade main beam 12, the blade shell 11 and the connector 2, can make the connection between the connector 2 and the blade 1 simpler. In addition, the blade 1 and the connector 2 can also be transported separately and assembled after being transported to the installation site.

[0081] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0082] The above is a detailed introduction to an ultra-long carbon fiber blade and a manufacturing method thereof provided by the present invention. This article uses specific examples to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only used to help understand the method of the present invention and its core idea. It should be pointed out that for ordinary technicians in this technical field, without departing from the principles of the present invention, several improvements and modifications can be made to the present invention, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. An ultra-long carbon fiber blade, characterized in that: include: Leaf body (1); A connector (2), a first end of which is plug-connected to the blade body (1) as a whole; The blade tip (3) comprises a first blade tip shell (31), a second blade tip shell (32) and a blade tip main beam (33), wherein the blade tip main beam (33) is formed by plugging a plurality of sub-beams (331) end to end in sequence, and the head end of the first sub-beam (331) is plugged and connected to the second end of the connector (2) as a whole, the first blade tip shell (31) and the second blade tip shell (32) are buckled and wrapped around the outer periphery of the blade tip main beam (33), and the gap between the two and the blade body (1) is sealed by a sealing tape.

2. The ultra-long carbon fiber blade according to claim 1, characterized in that: Each section of the sub-beam (331) is a hollow tube structure, and the diameter of the blade tip main beam (33) gradually decreases in the direction from the head end to the tail end.

3. The ultra-long carbon fiber blade according to claim 2, characterized in that: The connecting body (2) is a hollow tube structure, and the diameter of the second end of the connecting body (2) is larger than the diameter of the first end of the first section of the sub-beam (331).

4. The ultra-long carbon fiber blade according to claim 1, characterized in that: An elastic buckle is provided on the outer wall of the head end of one section of the sub-beam (331), and a clamping groove is provided on the inner wall of the tail end of another section of the sub-beam (331) adjacent to the head end of one section of the sub-beam (331), wherein the clamping groove is clamped and adapted to the elastic buckle.

5. The ultra-long carbon fiber blade according to claim 1, characterized in that: The insertion joints of two adjacent sub-beams (331) are fixedly connected by gluing.

6. The ultra-long carbon fiber blade according to claim 1, characterized in that: The front end and the rear end of each segment of the sub-beam (331) are both provided with chamfers.

7. The ultra-long carbon fiber blade according to any one of claims 1 to 6, characterized in that: The blade (1) comprises a blade shell (11) and two blade main beams (12); the two blade main beams (12) are arranged oppositely in the blade shell (11) and are integrally cast therewith; a gap is left between the two blade main beams (12) for the first end of the connector (2) to be inserted; the first end of the connector (2) is integrally cast with the blade main beam (12) and the blade shell (11); or the first end of the connector (2) is fixedly connected to the blade main beam (12) by gluing.

8. The ultra-long carbon fiber blade according to claim 7, characterized in that: Each segment beam (331) is a carbon fiber pultruded profile; and the blade body main beam (12) is a carbon fiber pultruded profile or a glass fiber pultruded profile.

9. A method for manufacturing an ultra-long carbon fiber blade, characterized in that: Used to manufacture the ultra-long carbon fiber blade according to any one of claims 1 to 8, comprising: The blade body and the connecting body are prefabricated in the factory using the blade body mold; Prefabricating a first blade tip shell and a second blade tip shell respectively using a blade tip shell mold in a factory; Multiple sections of beams are processed in the workshop; Transporting the blade body and the connecting body integrally connected therewith, the first blade tip shell, the second blade tip shell and the plurality of sections of the sub-beams to an installation site; Insert the head end of the first segment of the sub-beam into the connector, then insert the head and tail of the remaining sub-beams to form a blade tip main beam, and glue the insertion points of the sub-beams of each segment to fix them; Applying glue on the first blade tip shell and the second blade tip shell, and then buckling and wrapping the first blade tip shell and the second blade tip shell around the outer periphery of the blade tip main beam; Glass fiber cloth is hand-laid at the gaps between the first blade tip shell, the second blade tip shell and the blade body, and then the glass fiber cloth is cured to complete the on-site installation.

10. The method for manufacturing an ultra-long carbon fiber blade according to claim 9, characterized in that: The steps of prefabricating the blade body and the connecting body connected as one body by using the blade body mold in the factory specifically include: Injection molding the blade body main beam and the blade body shell into a single piece on the blade body mold; Processing the connector; Glue is applied to one end of the connector, and then the one end of the connector is inserted into the blade body shell.

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