Method for producing composite core material, and composite core material

Abstract

The invention provides a manufacturing method of a composite core material and the composite core material. The method comprises the following steps: providing a raw material base material and a reinforced angle material; the raw material base material is provided with two adjacent attaching faces, and the reinforcing angle section is provided with two attaching parts which intersect and are connected. The two attaching parts and the two attaching faces are in one-to-one correspondence and are fixedly connected to prepare an intermediate; stacking and fixedly connecting a plurality of intermediates to prepare a combined body; in any two adjacent intermediates, the raw material base material of one intermediate is connected with the reinforced angle section of the other intermediate; cutting the combined body to prepare a first composite core material; the method is few in step flow and simple in process, the manufacturing efficiency of the composite core material is improved, and the composite core material manufactured based on the method is high in structural strength, high in mechanical property and wide in application.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of composite material manufacturing, and in particular to a manufacturing method of a composite core material and the composite core material. BACKGROUND

[0002] At present, as an important component of the sandwich structure of the composite material structure, the core material has been widely used in the automobile, aircraft, ship, high-speed rail, building, wind power and other industries. Among them, the foam core material is often used in the manufacturing of wind power blades due to its low density characteristics, so as to reduce the overall weight of the wind power blade.

[0003] However, the manufacturing method of the foam core material in the related art is complex, and the foam core material manufactured has low structural strength, which can only be used in small load parts (such as near the blade tip) of the blade structure, and cannot be used in large load parts (such as near the blade root) of the blade structure. SUMMARY

[0004] The present application provides a manufacturing method of a composite core material and the composite core material, which is used to solve the problem of complex method process and low structural strength of the manufactured core material.

[0005] In order to achieve the above-mentioned purpose, the embodiments of the present application adopt the following technical solutions: In a first aspect, the embodiments of the present application provide a manufacturing method of a composite core material, comprising: providing a raw material base material and a reinforcing angle material; the raw material base material has two adjacent bonding surfaces, and the reinforcing angle material has two intersecting and connected bonding parts; the two bonding parts are fixedly connected with the two bonding surfaces one by one to prepare an intermediate body; a plurality of intermediate bodies are stacked and fixedly connected to prepare a combination body; in any two adjacent intermediate bodies, the raw material base material of one intermediate body is connected with the reinforcing angle material of the other intermediate body; and the combination body is cut to prepare a first composite core material.

[0006] In some possible implementation manners of the first aspect, the plurality of intermediate bodies are stacked and fixedly connected to prepare the combination body, comprising: the plurality of intermediate bodies are arranged along a first direction and sequentially fixedly connected to prepare a combination sheet; and the plurality of combination sheets are arranged along a second direction and sequentially fixedly connected to prepare the combination body; the first direction intersects the second direction.

[0007] In some possible implementation manners of the first aspect, the combination body is cut, comprising: the combination body is cut along a direction parallel to the first direction and parallel to the second direction.

[0008] In some possible implementation manners of the first aspect, the shape of the cross section of the raw material base material is rectangular, parallelogram, triangular, pentagonal or hexagonal.

[0009] In some possible implementation manners of the first aspect, a length of any side of the shape of the cross section of the raw material substrate is greater than or equal to 5 mm and less than or equal to 200 mm.

[0010] In some possible implementation manners of the first aspect, the raw material substrate is one or more of PVC foam, PET foam, PU foam, PMI foam, SAN foam, HPE foam, PS foam, PA foam or PP foam.

[0011] In some possible implementation manners of the first aspect, a density of the raw material substrate is greater than or equal to 20 kg / m 3 and less than or equal to 200 kg / m 3 .

[0012] In some possible implementation manners of the first aspect, an included angle between the two bonding portions is greater than or equal to 10° and less than or equal to 170°.

[0013] In some possible implementation manners of the first aspect, the reinforcing angle material is manufactured from a fiber fabric and a resin.

[0014] In some possible implementation manners of the first aspect, the fiber in the fiber fabric is one or more of glass fiber, carbon fiber, basalt fiber, natural fiber, ultra-high molecular weight polyethylene fiber, aramid fiber or polyester fiber; and the fiber fabric is one or more of unidirectional cloth, biaxial cloth, triaxial cloth, four-axis cloth, plain cloth, twill cloth, continuous felt or chopped felt.

[0015] In some possible implementation manners of the first aspect, the resin is one or more of epoxy resin, vinyl resin, unsaturated polyester resin, polyurethane resin, phenolic resin, acrylic resin, polyimide resin, cyclopentadiene resin or polyurea resin.

[0016] In some possible implementation manners of the first aspect, the manufacturing process of the reinforcing angle material is prepreg molding, vacuum infusion molding, hand lay-up molding, injection molding or compression molding.

[0017] In some possible implementation manners of the first aspect, the two bonding portions are fixedly connected with the two bonding surfaces one by one to prepare the intermediate body, including: bonding the two bonding portions with the two bonding surfaces one by one by means of an adhesive to prepare the intermediate body.

[0018] In some possible implementation manners of the first aspect, the plurality of intermediate bodies are stacked and fixedly connected to prepare the combination body, including: stacking the plurality of intermediate bodies and bonding the plurality of intermediate bodies by means of an adhesive to prepare the combination body.

[0019] In some possible implementation manners of the first aspect, the adhesive comprises one or more of an epoxy glue, a vinyl glue, an acrylic glue, a polyurethane glue, or a wood glue.

[0020] In some possible implementation manners of the first aspect, after the cutting of the combination, the method further comprises: opening a profiled groove on one side surface of the first composite core material along a third direction to obtain a second composite core material, the third direction intersects with the first direction and intersects with the second direction.

[0021] In some possible implementation manners of the first aspect, the profiled groove is a plurality of first profiled grooves and / or a plurality of second profiled grooves, the plurality of first profiled grooves are parallel to each other and arranged at intervals along the first direction, and the plurality of second profiled grooves are parallel to each other and arranged at intervals along the second direction.

[0022] In the second aspect, the embodiments of the present application provide a composite core material, which is manufactured by the method for manufacturing a composite core material of the first aspect; the composite core material comprises a plurality of raw material substrates; and a bonding portion is arranged between any two adjacent raw material substrates.

[0023] The method for manufacturing a composite core material and the composite core material provided by the present application have the following beneficial effects: The method for manufacturing a composite core material provided by the present application has the following beneficial effects: The method for manufacturing a composite core material provided by the present application has the following beneficial effects:

[0024] Figure 1 The flowchart of the method for manufacturing a composite core material provided by some embodiments of the present application is shown.

[0025] Figure 2 The structural schematic diagram of the raw material substrate of the composite core material provided by some embodiments of the present application is shown.

[0026] Figure 3 The structural schematic diagram of the reinforcing angle material of the composite core material provided by some embodiments of the present application is shown.

[0027] Figure 4Structure diagram of an intermediate of a composite core material provided for some embodiments of the present application.

[0028] Figure 5 Structure diagram of an assembly of a composite core material provided for some embodiments of the present application.

[0029] Figure 6 Structure diagram of a first composite core material provided for some embodiments of the present application.

[0030] Figure 7 Flow chart of another manufacturing method of a composite core material provided for some embodiments of the present application.

[0031] Figure 8 Structure diagram of an assembly of a composite core material provided for some embodiments of the present application.

[0032] Figure 9 Structure diagram of another assembly of a composite core material provided for some embodiments of the present application.

[0033] Figure 10 Flow chart of another manufacturing method of a composite core material provided for some embodiments of the present application.

[0034] Figure 11 Structure diagram of a second composite core material provided for some embodiments of the present application.

[0035] Explanation of reference numerals Raw material substrate 1; first bonding surface 11; second bonding surface 12; third bonding surface 13; fourth bonding surface 14; reinforcing angle material 2; first bonding portion 21; second bonding portion 22; intermediate 3; assembly sheet 4; first surface 41; second surface 42; third surface 43; fourth surface 44; assembly 5; cutting line 51; first composite core material 6; second composite core material 7; reinforcing rib 71; foam substrate 72; profiled groove 73; first profiled groove 731; second profiled groove 732. DETAILED DESCRIPTION

[0036] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments of the present application.

[0037] In the present application, the drawings are not necessarily drawn to scale, and local features can be enlarged or reduced to more clearly show the details of the local features.

[0038] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used in the description of the application herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. As used in the description of the application and the appended claims, the singular forms "a", "an" and "the" are used herein to include plural references unless the context clearly dictates otherwise. Thus, for example, reference to "a" or "the" includes one or more such items, irrespective of whether additional items can be present or not.

[0039] In the description of the application, it should be understood that the terms "first", "second" are used only for the purpose of description, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Therefore, the features defined with "first", "second" can explicitly or implicitly include one or more of the features. In the description of the application, the meaning of "multiple" is two or more, unless otherwise specifically limited. In the description of the application, the meaning of "several" is one or more, unless otherwise specifically limited.

[0040] In the description of the application, the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "height", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise" and the like indicate the orientation or positional relationship shown in the drawings, which is only for the convenience of the simplified description of the application, and does not indicate that the indicated device or element must have a particular orientation, be constructed and operated in a particular orientation, that is, cannot be understood as limiting the application.

[0041] In the description of the application, unless otherwise specifically limited, the terms "mounting", "connection", "connection", "fixing", "setting" and the like should be broadly understood. For example, "connection" can be fixed connection, or detachable connection, or integral; can be mechanical connection, or electrical connection; can be directly connected, or indirectly connected through intermediate medium, or internal communication of two elements or interaction relationship between two elements. For those skilled in the art, the specific meaning of the above terms in the application can be understood according to the specific circumstances.

[0042] In the description of the present application, unless otherwise explicitly defined, the first feature is "on", "over", "above" and "on top of", "under", "below", "under" or "under" the second feature can be the first feature and the second feature directly contact, or the first feature and the second feature indirectly contact through an intermediate medium. Moreover, the first feature is "on", "over" and "above" the second feature can be the first feature directly above or obliquely above the second feature, or just means that the horizontal height of the first feature is higher than the horizontal height of the second feature. The first feature is "below", "below" and "below" the second feature can be the first feature directly below or obliquely below the second feature, or just means that the horizontal height of the first feature is less than the horizontal height of the second feature.

[0043] At present, as an important part of the sandwich structure of the composite material structure, the core material has been widely used in the automobile, airplane, ship, high-speed rail, building, wind power and other industries. Among them, the foam core material is often used in the manufacture of wind power blades due to its low density characteristics, so as to reduce the overall weight of the wind power blade.

[0044] However, the manufacturing method of the foam core material in the related art is complex, and the foam core material structure has low strength, which can only be used in small load parts of the blade structure (such as near the blade tip), and cannot be used in large load parts of the blade structure (such as near the blade root).

[0045] In order to solve the above problems, some embodiments of the present application provide a manufacturing method of a composite core material and a composite core material (such as including a first composite core material and a second composite core material), by fixing and connecting the reinforcing angle material and the raw material substrate to prepare an intermediate body, so as to improve the structural strength of the intermediate body to a certain extent; then, by stacking and fixing a plurality of intermediate bodies, a combined body is prepared, in any two adjacent intermediate bodies of the combined body, the raw material substrate of one intermediate body is connected with the reinforcing angle material of the other intermediate body, so that a plurality of reinforcing angle materials can be uniformly distributed in the combined body, which is beneficial to improve the structural strength of the combined body; finally, the combined body is cut into a first composite core material by cutting. In this way, the manufacturing method of the composite core material has few steps and simple process, thereby improving the manufacturing efficiency of the composite core material, and the composite core material (such as including a first composite core material) manufactured based on the method has high structural strength, strong mechanical properties and wide application.

[0046] The technical solutions in the embodiments of the present application will be described clearly and completely in combination with the drawings in the embodiments of the present application.

[0047] Please refer to Figure 1 , Figure 1 The flow chart of the manufacturing method of the composite core material provided by some embodiments of the present application is shown in FIG. 1. The manufacturing method of the composite core material includes steps S10 to S40.

[0048] In step S10, a raw material substrate and a reinforcing angle are provided. The raw material substrate has two adjacent bonding surfaces, and the reinforcing angle has two intersecting and connected bonding portions.

[0049] Figure 2 This is a schematic diagram of the structure of the raw material substrate 1 of the composite core material provided in some embodiments of this application; Figure 3 This is a schematic diagram of the structure of the reinforcing angle 2 of the composite core material provided in some embodiments of this application.

[0050] For example, such as Figure 2 and Figure 3 As shown, the two bonding surfaces of the raw material substrate 1 are the first bonding surface 11 and the second bonding surface 12, respectively. The two bonding portions of the reinforcing angle 2 are the first bonding portion 21 and the second bonding portion 22, respectively.

[0051] In step S20, the two bonding parts are matched one-to-one with the two bonding surfaces and fixedly connected to prepare the intermediate body.

[0052] In this way, by corresponding and fixing the two bonding parts to the two bonding surfaces, the fixed connection between the reinforcing angle and the raw material substrate can be achieved, thereby improving the structural strength of the prepared intermediate to a certain extent.

[0053] Figure 4 This is a schematic diagram of the structure of intermediate 3 of the composite core material provided in some embodiments of this application.

[0054] In some embodiments, such as Figure 4 As shown, the first bonding surface 11 corresponds to and is fixedly connected to the first bonding part 21, and the second bonding surface 12 corresponds to and is fixedly connected to the second bonding part 22.

[0055] In some embodiments, the first bonding surface 11 is bonded to the first bonding portion 21 by an adhesive, and the second bonding surface 12 is bonded to the second bonding portion 22 by an adhesive to prepare the intermediate 3. For example, the adhesive includes one or more of epoxy resin, vinyl resin, acrylic resin, polyurethane resin, or wood glue.

[0056] In some embodiments, when the raw material substrate 1 is a PET foam part, the raw material substrate 1 and the reinforcing angle 2 can be fixedly connected by hot melt bonding.

[0057] In some embodiments, when the material of the reinforcing angle 2 includes a thermoplastic resin (such as polyimide resin), the raw material substrate 1 and the reinforcing angle 2 can be fixedly connected by hot melt bonding.

[0058] In step S30, multiple intermediates are stacked and fixedly connected to prepare an assembly.

[0059] For example, in any two adjacent intermediates, the raw material substrate of one intermediate is connected to the reinforcing angle of the other intermediate. In this way, multiple reinforcing angles can be evenly distributed in the assembly, which helps to improve the structural strength of the assembly.

[0060] Figure 5 This is a schematic diagram of the structure of the composite core material assembly 5 provided in some embodiments of this application.

[0061] For example, such as Figure 1 and Figure 5 As shown, the raw material substrate 1 also includes a third bonding surface 13 and a fourth bonding surface 14. The third bonding surface 13 is disposed opposite to the first bonding surface 11 along the second direction Y, and the fourth bonding surface 14 is disposed opposite to the second bonding surface 12 along the first direction X.

[0062] Multiple intermediate bodies 3 are arranged in multiple columns along the first direction X and in multiple rows along the second direction Y. In one intermediate body 3, the first bonding portion 21 is fixedly connected to the third bonding surface 13 of the adjacent intermediate body 3, and the second bonding portion 22 is fixedly connected to the fourth bonding surface 14 of the adjacent intermediate body 3. Similarly, in one intermediate body 3, the third bonding surface 13 is fixedly connected to the first bonding portion 21 of the adjacent intermediate body 3, and the fourth bonding surface 14 is fixedly connected to the second bonding portion 22 of the adjacent intermediate body 3.

[0063] For example, the first direction X intersects with the second direction Y.

[0064] It is understandable that the above arrangement allows multiple reinforcing angle members 2 to be arranged in a grid pattern in the assembly 5 (and the first composite core material 6), which is beneficial to improving the uniformity of the distribution of multiple reinforcing angle members 2 in the assembly 5 and improving the structural strength of the assembly 5 and the first composite core material 6.

[0065] In some embodiments, multiple intermediates 3 are bonded together as an assembly 5 using an adhesive. It should be noted that the type of adhesive used for bonding the multiple intermediates 3 and the bonding method can be referenced to the adhesive and bonding method used for bonding the raw material substrate 1 and the reinforcing angle 2 in some of the embodiments above, and will not be repeated here.

[0066] In step S40, the assembly is cut to obtain the first composite core material.

[0067] Figure 6 A schematic diagram of the structure of the first composite core material 6 provided in some embodiments of this application.

[0068] For example, such as Figure 5 and Figure 6As shown, the assembly 5 has multiple pre-cut surfaces 51, which are parallel to the first direction X and the second direction Y. Thus, the first composite core material 6 is produced by cutting the assembly 5 along the pre-cut surfaces 51.

[0069] It is understandable that the manufacturing method of the composite core material described above has fewer steps and simpler processes, which is conducive to improving the manufacturing efficiency of the composite core material. Furthermore, the composite core material manufactured based on this method (such as including the first composite core material) has high structural strength, strong mechanical properties, and wide range of applications.

[0070] For example, composite core materials can be used as the core material of wind turbine blades, and composite core materials can be used in any part of the blade structure.

[0071] Please see Figure 7 and Figure 8 , Figure 7 A flowchart illustrating another method for manufacturing a composite core material according to some embodiments of this application. Figure 8 This is a schematic diagram of the structure of a composite core material combined sheet provided in some embodiments of this application. Step S30 includes steps S31 and S32.

[0072] In step S31, multiple intermediate bodies are arranged along the first direction and fixedly connected in sequence to prepare a composite sheet.

[0073] For example, see Figure 8 The first bonding portions 21 of the plurality of intermediate bodies 3 are arranged along the first direction X to form the first surface 41 of the composite sheet 4. The third bonding surfaces 13 of the plurality of intermediate bodies 3 are arranged along the first direction X to form the third surface 43 of the composite sheet 4. Among the plurality of intermediate bodies 3, the surfaces of two intermediate bodies 3 located at their ends along the second direction Y, facing away from each other, form the second surface 42 and the fourth surface 44 of the composite sheet 4.

[0074] In some embodiments, multiple intermediates 3 are bonded together to form a composite sheet 4 using an adhesive. It should be noted that the type of adhesive used for bonding the multiple intermediates 3 and the bonding method can be referenced to the adhesive and bonding method used for bonding the raw material substrate 1 and the reinforcing angle 2 in some of the embodiments above, and will not be repeated here.

[0075] In step S32, multiple composite sheets 4 are arranged along the second direction and fixedly connected in sequence to prepare the composite body 5.

[0076] For example, see Figure 5 and Figure 8Multiple composite sheets 4 are arranged along the second direction Y; the first surface 41 of any composite sheet 4 is fixedly connected to the third surface 43 of an adjacent composite sheet 4; the third surface 43 of any composite sheet 4 is fixedly connected to the first surface 41 of an adjacent composite sheet 4.

[0077] It is understandable that the above arrangement allows multiple reinforcing angle members 2 to be arranged in a grid pattern in the assembly 5 (and the first composite core material 6), which is beneficial to improving the uniformity of the distribution of multiple reinforcing angle members 2 in the assembly 5 and improving the structural strength of the assembly 5 and the first composite core material 6.

[0078] In some embodiments, multiple composite sheets 4 are bonded together to form an assembly 5 using an adhesive. It should be noted that the type of adhesive used for bonding the multiple composite sheets 4 and the bonding method can be referenced to the adhesive and bonding method used for bonding the raw material substrate 1 and the reinforcing angle 2 in some of the embodiments above, and will not be repeated here.

[0079] In some embodiments, the cross-sectional shape of the raw material substrate 1 is rectangular, parallelogram, triangle, pentagon or hexagonal.

[0080] It is understandable that by setting the cross-sectional shape of the raw material substrate 1 to a rectangle, parallelogram, triangle, pentagon or hexagon, the bonding surface can be a flat surface, which facilitates the fixed connection of the two bonding parts of the raw material substrate 1 with the two bonding surfaces of the reinforcing angle 2, thereby improving the manufacturing efficiency of the first composite core material 6 and thus improving the structural strength of the first composite core material 6.

[0081] It should be noted that the cross-section of raw material substrate 1 refers to the cross-section perpendicular to the extension direction of raw material substrate 1.

[0082] In some embodiments, such as Figure 3 and Figure 4 As shown, the included angle between the first fitting portion 21 and the second fitting portion 22 (i.e., the two fitting portions) is greater than or equal to 10° and less than or equal to 170°. For example, the included angle between the first fitting portion 21 and the second fitting portion 22 is 10°, 30°, 60°, 90°, 135°, or 170°. This facilitates the fitting of the two fitting portions with the two fitting surfaces and their fixed connection.

[0083] In some embodiments, such as Figure 2 to Figure 4As shown, the cross-section of the raw material substrate 1 is rectangular, and the included angle between the first bonding portion 21 and the second bonding portion 22 (i.e., the two bonding portions) is 90°. This facilitates the stacking of multiple intermediate bodies 3 in step S30, which is beneficial to improving the manufacturing efficiency of the composite core material 6, and allows the reinforcing angle members 2 to be arranged in a grid pattern in the composite core material 6, thereby improving the structural strength of the composite core material 6.

[0084] Please see Figure 9 , Figure 9 This is a schematic diagram of another assembly of composite core materials provided in some embodiments of this application. The cross-section of the raw material substrate 1 is a parallelogram, and the included angle between the first bonding portion 21 and the second bonding portion 22 (i.e., the two bonding portions) is an acute angle. In this way, the proportion of the reinforcing angle member 2 in the assembly 5 and the first composite core material 6 can be increased, thereby improving the structural strength of the first composite core material 6.

[0085] In some embodiments, the length of any side of the cross-section of the raw material substrate 1 is greater than or equal to 5 mm and less than or equal to 200 mm. For example, the length of any side of the cross-section of the raw material substrate 1 is 5 mm, 10 mm, 20 mm, 50 mm, 100 mm or 200 mm.

[0086] Thus, on the one hand, by setting the length of any side of the cross-sectional shape of the raw material substrate 1 to be greater than or equal to 5 mm, it is beneficial to improve the structural strength of the raw material substrate 1. Furthermore, the raw material substrate 1 can have a certain size to facilitate the bonding operation between the bonding surface and the bonding portion of the reinforcing angle 2, thereby improving the stability and reliability of the fixed connection between the raw material substrate 1 and the reinforcing angle 2. On the other hand, by setting the length of any side of the cross-sectional shape of the raw material substrate 1 to be less than or equal to 200 mm, the distribution density of the reinforcing angle 2 in the composite core material 6 can be increased, thereby improving the overall structural strength of the first composite core material 6.

[0087] In some embodiments, the raw material substrate 1 is one or more of PVC foam, PET foam, PU foam, PMI foam, SAN foam, HPE foam, PS foam, PA foam, or PP foam. This allows the raw material substrate 1 to have a lower density, which in turn helps to reduce the density of the first composite core material 6, enabling the first composite core material 6 to have a wide range of applications.

[0088] In some embodiments, the density of the raw material substrate 1 is greater than or equal to 20 kg / m³. 3 And less than or equal to 200 kg / m 3 For example, the density of raw material substrate 1 is 20 kg / m³. 3 50 kg / m 3100 kg / m 3 Or 200 kg / m 3 This allows the raw material substrate 1 to have a lower density, thereby reducing the density of the first composite core material 6 to some extent.

[0089] In some embodiments, the reinforcing angle 2 is made of fiber fabric and resin.

[0090] It is understandable that fiber fabric can improve the strength and modulus of reinforced angle 2, and resin can further improve the strength of reinforced angle 2 and play a role in transferring load. Thus, the combination of fiber fabric and resin is conducive to improving the mechanical properties of the reinforced angle itself, enabling it to effectively bear and distribute external loads.

[0091] In some embodiments, the fibers in the fiber fabric are one or more selected from glass fiber, carbon fiber, basalt fiber, natural fiber, ultra-high molecular weight polyethylene fiber, aramid fiber, or polyester fiber. The fiber fabric is one or more selected from unidirectional fabric, biaxial fabric, triaxial fabric, quadriaxial fabric, plain weave fabric, twill weave fabric, continuous felt, or chopped strand mat. This provides the limiting fabric with a certain structural strength and helps reduce the manufacturing cost of the reinforcing angle 2.

[0092] In some embodiments, the resin is one or more of epoxy resin, vinyl resin, unsaturated polyester resin, polyurethane resin, phenolic resin, acrylic resin, polyimide resin, cyclopentadiene resin, or polyurea resin.

[0093] In some embodiments, the reinforcing angle 2 is manufactured using a prepreg molding process. The prepreg molding process includes: first, placing a dry fiber fabric in a liquid resin raw material for impregnation; after the fiber fabric has absorbed a sufficient amount of liquid resin raw material, then laying and curing the fiber fabric. This improves the production efficiency of the reinforcing angle 2 and can, to a certain extent, increase the amount of resin material absorbed by the fiber fabric, thereby improving the structural strength and mechanical properties of the reinforcing angle 2.

[0094] In some embodiments, the reinforcing angle 2 is manufactured using a vacuum injection molding process. The vacuum injection molding process includes: placing a dry fiber fabric into an injection mold; evacuating the mold to remove air from the mold and the fiber fabric; then, injecting liquid resin into the mold under vacuum; and finally, curing the fiber fabric after it has absorbed a sufficient amount of liquid resin. This improves the uniformity of resin distribution within the fiber fabric and, to some extent, avoids defects such as air bubbles between the fiber fabric and resin that could affect strength, thereby improving the structural strength and mechanical properties of the reinforcing angle 2.

[0095] In some embodiments, the reinforcing angle 2 is manufactured by a hand lay-up molding process. The hand lay-up molding process includes manually applying resin to a fiber fabric and then curing the resin. The equipment and tools required for the hand lay-up molding process are simple and inexpensive.

[0096] In some embodiments, the reinforcing angle 2 is manufactured by injection molding. The injection molding process includes mixing chopped fiber fabric with resin and injecting the mixture into a mold, followed by curing the resin. Injection molding offers high production efficiency and facilitates the production of complex shapes and structures.

[0097] In some embodiments, the reinforcing angle 2 is manufactured by a compression molding process. The compression molding process includes: placing a pre-impregnated resin-coated fiber fabric into a mold cavity; subsequently, closing the mold to allow the resin to fill the cavity; and finally, applying high temperature and high pressure to the mold to cure the resin. The compression molding process can improve the surface quality of the reinforcing angle 2, giving it excellent mechanical properties.

[0098] Please see Figure 10 , Figure 10 This is a flowchart illustrating another method for manufacturing a composite core material according to some embodiments of this application. Following step S40, the method for manufacturing the composite core material further includes step S50.

[0099] In step S50, a conformal groove is formed on one side surface of the first composite core material along a third direction to produce the second composite core material.

[0100] It is understandable that the conformal groove allows the second composite core material 7 to be bent into the desired profile. That is, the second composite core material 7 can be used as the core material profile plate of wind turbine blades for the production of wind turbine blade shells and webs, thus enriching the application scenarios of composite core materials.

[0101] Please see Figure 11 , Figure 11 This is a schematic diagram of the structure of the second composite core material 7 provided in some embodiments of this application. The conformal groove 73 comprises a plurality of first conformal grooves 731 and / or a plurality of second conformal grooves 732; the plurality of first conformal grooves 731 are parallel to each other and spaced apart along a first direction X; the plurality of second conformal grooves 732 are parallel to each other and spaced apart along a second direction Y. For example, the third direction Z intersects the first direction X and the second direction Y. This allows the second composite core material 7 to be bent into any desired profile.

[0102] Some embodiments of this disclosure also provide a composite core material, which can be manufactured by the manufacturing method of the composite core material described in any of the above embodiments.

[0103] like Figure 6As shown, the composite core material can be a first composite core material 6. The first composite core material 6 includes multiple raw material substrates 1; an adhesive portion is provided between any two adjacent raw material substrates 1. The multiple adhesive portions form a grid-like reinforcing structure. This is beneficial for improving the structural strength and mechanical properties of the first composite core material 6.

[0104] like Figure 11 As shown, the composite core material can be a second composite core material 7. The second composite core material 7 includes a foam substrate 72 (i.e., raw material substrate 1), reinforcing ribs 71 (i.e., bonding portion) and conformal grooves 73.

[0105] The reinforcing ribs 71 are disposed in the foam substrate 72. The reinforcing ribs 71 include a plurality of first reinforcing ribs 711 and a plurality of second reinforcing ribs 712. The plurality of first reinforcing ribs 711 are parallel to each other and spaced apart along a first direction X; the plurality of second reinforcing ribs 712 are parallel to each other and spaced apart along a second direction Y.

[0106] The conformal groove 73 is disposed on the surface of the foam substrate 72 along the third direction Z. The conformal groove 73 includes a plurality of first conformal grooves 731 and / or a plurality of second conformal grooves 732. The plurality of first conformal grooves 731 are parallel to each other and spaced apart along the first direction X; the plurality of second conformal grooves 732 are parallel to each other and spaced apart along the second direction Y.

[0107] In the first direction X, multiple first conforming grooves 731 and multiple first reinforcing ribs 711 are staggered, and multiple second conforming grooves 732 and multiple second reinforcing ribs 712 are staggered. In this way, the influence of conforming grooves 73 on the structural strength of the second composite core material 7 can be reduced to a certain extent.

[0108] It is understandable that during the manufacturing process of wind turbine blades, the conformal groove 73 is filled with resin. After the resin is cured, it can further enhance the second composite core material 7, thereby improving the structural strength and mechanical properties of the wind turbine blades.

[0109] It is understood that in the various embodiments of this application, the sequence number of each process does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0110] It is understood that the various implementation methods described in this application can be implemented individually or in combination, and the embodiments of this application are not limited in this respect.

[0111] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the aforementioned method implementations, and will not be repeated here.

[0112] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A method for manufacturing a composite core material, characterized in that, include: A raw material substrate and a reinforcing angle are provided; wherein the raw material substrate has two adjacent bonding surfaces, and the reinforcing angle has two intersecting and connected bonding portions; The two bonding portions are corresponding one-to-one with the two bonding surfaces and fixedly connected to prepare an intermediate body; Multiple intermediates are stacked and fixedly connected to prepare an assembly; wherein, in any two adjacent intermediates, the raw material substrate of one intermediate is connected to the reinforcing angle of the other intermediate. The assembly is cut to produce a first composite core material.

2. The method for manufacturing the composite core material according to claim 1, characterized in that, The step of stacking and fixing multiple intermediates together to prepare an assembly includes: Multiple intermediate bodies are arranged along a first direction and sequentially fixed and connected to prepare a composite sheet. Multiple composite sheets are arranged along a second direction and sequentially fixed together to prepare the composite body; Wherein, the first direction intersects with the second direction.

3. The method for manufacturing the composite core material according to claim 2, characterized in that, The cutting of the assembly includes: The assembly is cut along a direction parallel to the first direction and parallel to the second direction.

4. The method for manufacturing the composite core material according to claim 1, characterized in that, The cross-sectional shape of the raw material substrate is rectangular, parallelogram, triangle, pentagon or hexagonal.

5. The method for manufacturing the composite core material according to claim 4, characterized in that, The length of any side of the cross-section of the raw material substrate is greater than or equal to 5 mm and less than or equal to 200 mm.

6. The method for manufacturing the composite core material according to claim 1, characterized in that, The raw material base material is one or more of PVC foam, PET foam, PU foam, PMI foam, SAN foam, HPE foam, PS foam, PA foam or PP foam.

7. The method for manufacturing the composite core material according to claim 1, characterized in that, The density of the raw material substrate is greater than or equal to 20 kg / m³. 3 And less than or equal to 200 kg / m 3 .

8. The method for manufacturing the composite core material according to claim 1, characterized in that, The included angle between the two fitting parts is greater than or equal to 10° and less than or equal to 170°.

9. The method for manufacturing the composite core material according to claim 1, characterized in that, The reinforcing angle material is made of fiber fabric and resin.

10. The method for manufacturing the composite core material according to claim 9, characterized in that, The fibers in the fiber fabric are one or more of the following: glass fiber, carbon fiber, basalt fiber, natural fiber, ultra-high molecular weight polyethylene fiber, aramid fiber, or polyester fiber. The fiber fabric is one or more of the following: unidirectional fabric, biaxial fabric, triaxial fabric, quadriaxial fabric, plain weave fabric, twill fabric, continuous felt, or chopped strand mat.

11. The method for manufacturing the composite core material according to claim 9, characterized in that, The resin is one or more of epoxy resin, vinyl resin, unsaturated polyester resin, polyurethane resin, phenolic resin, acrylic resin, polyimide resin, cyclopentadiene resin, or polyurea resin.

12. The method for manufacturing the composite core material according to claim 9, characterized in that, The manufacturing process of the reinforced angle material is prepreg molding, vacuum injection molding, hand lay-up molding, injection molding, or compression molding.

13. The method for manufacturing the composite core material according to claim 1, characterized in that, The step of preparing an intermediate body by corresponding and fixing the two bonding portions to the two bonding surfaces one by one includes: The two bonding portions are matched one-to-one with the two bonding surfaces and bonded together with an adhesive to prepare an intermediate.

14. The method for manufacturing the composite core material according to claim 1, characterized in that, The step of stacking and fixing multiple intermediates together to prepare an assembly includes: Multiple intermediates are stacked and bonded together with an adhesive to form the assembly.

15. The method for manufacturing the composite core material according to claim 13 or 14, characterized in that, The adhesive includes one or more of epoxy resin, vinyl resin, acrylic resin, polyurethane resin, or wood adhesive.

16. The method for manufacturing the composite core material according to claim 1, characterized in that, After cutting the assembly, the method further includes: A conformal groove is formed on one side surface of the first composite core material along a third direction to produce the second composite core material; The third direction intersects with the first direction and also with the second direction.

17. The method for manufacturing the composite core material according to claim 16, characterized in that, The conformal groove is a plurality of first conformal grooves and / or a plurality of second conformal grooves; The plurality of first conformal grooves are parallel to each other and spaced apart along a first direction; the plurality of second conformal grooves are parallel to each other and spaced apart along a second direction.

18. A composite core material, characterized in that, The composite core material is manufactured by the method for manufacturing composite core material according to any one of claims 1-17; The composite core material includes a plurality of the raw material substrates (1); the bonding portion is provided between any two adjacent raw material substrates (1).

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