Manufacturing method of cork wood core material

Abstract

The invention provides a manufacturing method of a cork wood core material. The method comprises the steps that a cork wood sheet material is provided; the balsa wood sheet is subjected to potting treatment, so that a potting balsa wood sheet is prepared; removing a specific defect part of the potting cork wood sheet, and forming a maintenance hole; and the maintenance holes are subjected to filling treatment, so that the balsa wood core material is manufactured. Thus, according to the method, the balsa wood sheet is subjected to potting treatment firstly, so that the specific defect part of the balsa wood sheet appears, then the specific defect part is removed, the formed maintenance hole is subjected to filling treatment, and therefore the phenomenon that the balsa wood core material manufactured based on the manufacturing method has specific defects can be avoided; the structural strength and the mechanical property of the balsa wood core material are favorably improved.

Description

Technical Field

[0001] This application relates to the field of composite material manufacturing technology, specifically to a method for manufacturing balsa wood core material. Background Technology

[0002] Balsa wood (also known as balsa wood) is widely used as a core material for wind turbine blades due to its low density and high mechanical properties. However, balsa wood has a high moisture content and is prone to water absorption, and it is susceptible to localized deterioration during transportation and processing.

[0003] During the resin curing process of wind turbine blades, a large amount of heat is released when the resin cures, causing the moisture in the balsa wood to evaporate and producing specific defects (such as delamination and whitening defects). In addition, the resin may enter the interior of the balsa wood through the deterioration points, causing local resin accumulation and further accelerating the evaporation of moisture in the balsa wood, increasing the probability of the occurrence of specific defects.

[0004] However, since the dried balsa wood absorbs moisture from the air before entering the infusion process, and local deterioration is difficult to distinguish from appearance alone, it is difficult to determine before infusion whether a piece of balsa wood will develop specific defects after infusion. This can lead to specific defects in the balsa wood core material of some infused wind turbine blades, which seriously affects the structural strength of the wind turbine blades. Summary of the Invention

[0005] This application provides a method for manufacturing balsa wood core material to solve the problem of specific defects in balsa wood core material.

[0006] To achieve the above objectives, the embodiments of this application adopt the following technical solutions: In a first aspect, embodiments of this application provide a method for manufacturing balsa wood core material, the method comprising: providing balsa wood sheets; performing a potting process on the balsa wood sheets to obtain potted balsa wood sheets; the potted balsa wood sheets include balsa wood sheets and a potting layer; the potting layer at least covers both sides of the balsa wood sheets in the thickness direction; removing specific defective portions of the potted balsa wood sheets and forming repair holes; and filling the repair holes to obtain balsa wood core material.

[0007] In some possible implementations of the first aspect, filling the maintenance hole includes: cutting a spare potted balsa wood sheet to obtain a repair block without specific defects; adapting the shape of the repair block to the maintenance hole; and installing the repair block into the maintenance hole.

[0008] In some possible implementations of the first aspect, installing the repair block into the maintenance hole includes: bonding and fixing the repair block to the hole wall of the maintenance hole with an adhesive.

[0009] In some possible implementations of the first aspect, the adhesive is white glue and / or epoxy glue.

[0010] In some possible implementations of the first aspect, after providing the balsa wood sheets and before filling the balsa wood sheets to produce filled balsa wood sheets, the method further includes drying the balsa wood sheets.

[0011] In some possible implementations of the first aspect, the moisture content of the dried balsa wood sheets is less than or equal to 10%.

[0012] In some possible implementations of the first aspect, after the step of providing the balsa wood sheet and before drying the balsa wood sheet, the method includes: sanding the surface of the balsa wood sheet.

[0013] In some possible implementations of the first aspect, potting the balsa wood sheet to produce potted balsa wood sheet includes: sequentially stacking a first release structure, the balsa wood sheet, and a second release structure, and placing them between a first seal and a second seal; defining a receiving space between the first seal and the second seal, with the first release structure, the balsa wood sheet, and the second release structure located in the receiving space; evacuating the receiving space; injecting potting material into the receiving space; curing the potting material to form a potting layer; and removing the first release structure, the second release structure, the first seal, and the second seal.

[0014] In some possible implementations of the first aspect, both the first demolding structure and the second demolding structure include: a demolding cloth.

[0015] In some possible implementations of the first aspect, both the first demolding structure and the second demolding structure include: a flow guide, which is stacked with the demolding cloth, and the flow guide is located on the side of the demolding cloth opposite to the balsa wood sheet.

[0016] In some possible implementations of the first aspect, the potting layer material includes one or more of epoxy resin, unsaturated polyester resin, vinyl resin, polyurethane resin, cyclopentadiene resin, or acrylic resin.

[0017] In some possible implementations of the first aspect, after filling the maintenance hole to produce the balsa core, the method further includes: creating a conformal groove on one side surface of the balsa core in the thickness direction.

[0018] In some possible implementations of the first aspect, the thickness of the balsa sheet is greater than or equal to 5 mm and less than or equal to 60 mm.

[0019] The method for manufacturing balsa wood core material provided in this application has the following beneficial effects: The present application provides a method for manufacturing balsa wood core material, comprising: providing balsa wood sheets; performing a potting treatment on the balsa wood sheets to obtain potted balsa wood sheets; removing specific defective portions of the potted balsa wood sheets and forming repair holes; and filling the repair holes to obtain balsa wood core material. Thus, this method first exposes specific defective portions of the balsa wood sheets by performing a potting treatment, then removes the specific defective portions, and fills the formed repair holes. This avoids the occurrence of specific defects in the balsa wood core material manufactured using this method, thereby improving the structural strength and mechanical properties of the balsa wood core material. Attached Figure Description

[0020] Figure 1 A flowchart illustrating a method for manufacturing balsa wood core material according to some embodiments of this application.

[0021] Figure 2 for Figure 1 A schematic diagram of the structure of the potted balsa wood sheet obtained in step S2.

[0022] Figure 3 for Figure 1 A schematic diagram of the structure of the potted balsa wood sheet obtained in step S3 after removing the specific defective parts.

[0023] Figure 4 for Figure 1 A schematic diagram of the balsa wood core material obtained in step S4.

[0024] Figure 5 A flowchart illustrating another method for manufacturing balsa wood core material provided in some embodiments of this application.

[0025] Figure 6 A flowchart illustrating yet another method for manufacturing balsa wood core material, provided for some embodiments of this application.

[0026] Figure 7 A flowchart illustrating yet another method for manufacturing balsa wood core material, provided for some embodiments of this application.

[0027] Figure 8 A flowchart illustrating yet another method for manufacturing balsa wood core material, provided for some embodiments of this application.

[0028] Figure 9 for Figure 8 A schematic diagram of the potting system used in steps S21 to S25.

[0029] Figure 10 A flowchart illustrating yet another method for manufacturing balsa wood core material, provided for some embodiments of this application.

[0030] Figure 11 for Figure 10A schematic diagram of the balsa wood core material with a conformal groove obtained in step S5.

[0031] Explanation of reference numerals in the attached figures 1. Balsa wood core material; 10. Encapsulated balsa wood sheet; 11. Balsa wood sheet; 12. Encapsulation layer; 13. Specific defect portion; 14. Repair hole; 15. Conformal groove; 151. First conformal groove; 152. Second conformal groove; 16. Mesh fabric; 20. Repair block; Encapsulation system 100; containment space 100a; first demolding structure 110; demolding cloth 111; flow guide 112; second demolding structure 120; first seal 130; second seal 140; injection port 150; vent 160; sealing strip 170; flow guide tube 180; air guide tube 190. Detailed Implementation

[0032] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0033] In this application, the accompanying drawings are not necessarily drawn to scale, and local features may be enlarged or reduced to more clearly show the details of the local features.

[0034] Unless otherwise stated, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used in this application is for the purpose of describing particular embodiments only and is not intended to limit the scope of this application. The term "and / or" as used in this application includes any and all combinations of one or more of the associated listed items. The singular forms "a," "the," and "the" as used in this application and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise.

[0035] In the description of this application, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified. In the description of this application, "several" means one or more, unless otherwise explicitly specified.

[0036] In the description of this application, the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "height", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the purpose of simplifying the description of this application and do not indicate that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. In other words, they should not be construed as limitations on this application.

[0037] In the description of this application, unless otherwise expressly defined, the terms "installation," "connection," "linking," "fixing," "setting," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can also refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0038] In the description of this application, unless otherwise expressly defined, the terms "above," "over," "on top of," "below," "below," "under," or "below" for "first feature over second feature" can refer to the first and second features being in direct contact, or to the first and second features being in indirect contact through an intermediate medium. Furthermore, "above," "below," and "over" for "first feature over second feature" can mean the first feature is directly above or diagonally above the second feature, or simply indicates that the horizontal height of the first feature is higher than the horizontal height of the second feature. Similarly, "below," "below," and "below" for "first feature over second feature" can mean the first feature is directly below or diagonally below the second feature, or simply indicates that the horizontal height of the first feature is lower than the horizontal height of the second feature.

[0039] Balsa wood (also known as balsa wood) is widely used as a core material for wind turbine blades due to its low density and high mechanical properties. However, balsa wood has a high moisture content and is prone to water absorption, and it is susceptible to localized deterioration during transportation and processing.

[0040] During the resin curing process of wind turbine blades, a large amount of heat is released when the resin cures, causing the moisture in the balsa wood to evaporate and producing specific defects (such as delamination and whitening defects). In addition, the resin may enter the interior of the balsa wood through the deterioration points, causing local resin accumulation and further accelerating the evaporation of moisture in the balsa wood, increasing the probability of the occurrence of specific defects.

[0041] However, since the dried balsa wood absorbs moisture from the air before entering the infusion process, and local deterioration is difficult to distinguish from appearance alone, it is difficult to determine before infusion whether a piece of balsa wood will develop specific defects after infusion. This can lead to specific defects in the balsa wood core material of some infused wind turbine blades, which seriously affects the structural strength of the wind turbine blades.

[0042] To address the aforementioned issues, some embodiments of this application provide a method for manufacturing balsa wood core material. This method first involves potting balsa wood sheets to expose specific defective portions. Then, the defective portions are removed, and the resulting repair holes are filled. This method avoids the occurrence of specific defects in balsa wood core material manufactured using this method, thereby improving the structural strength and mechanical properties of the balsa wood core material.

[0043] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings.

[0044] Please see Figure 1 , Figure 1 This is a flowchart illustrating a method for manufacturing balsa wood core material according to some embodiments of this application. The method for manufacturing balsa wood core material includes steps S1 to S4.

[0045] In step S1, balsa wood sheets are provided.

[0046] Some embodiments of this application do not limit the method of providing balsa wood sheets. In some embodiments, balsa wood sheets can be obtained by cutting balsa wood squares.

[0047] For example, the thickness of the balsa wood sheet is greater than or equal to 5 mm and less than or equal to 60 mm. For instance, the thickness of the balsa wood sheet can be 5 mm, 10 mm, 20 mm, 30 mm, or 60 mm. This allows the balsa wood sheet to have a certain structural strength to meet the structural support requirements of the wind turbine blade sandwich.

[0048] In step S2, the balsa wood sheet is potted to produce potted balsa wood sheet; the potted balsa wood sheet includes the balsa wood sheet and the potting layer; the potting layer covers at least both sides of the balsa wood sheet in the thickness direction.

[0049] Please see Figure 2 , Figure 2 for Figure 1 A schematic diagram of the structure of the potted balsa wood sheet 10 obtained in step S2; the potted balsa wood sheet 10 includes a balsa wood sheet 11 and a potting layer 12 covering both sides of the balsa wood sheet 11 in the thickness direction. The potted balsa wood sheet 10 has specific defect portions 13.

[0050] It should be noted that the specific defective part 13 is, for example, the part of the potted balsa wood sheet 10 with delamination and whitening defects. Delamination and whitening defects refer to the phenomenon of white streaks, bubble accumulation, or poor fiber impregnation appearing at the interface between the balsa wood sheet 11 and the potting layer 12 due to factors such as internal moisture evaporation and localized deterioration during the potting process (which can also be equivalent to the vacuum injection molding process of wind turbine blades, in which case the balsa wood sheet 11 is directly used as the core material of the wind turbine blade). Delamination and whitening defects will reduce the structural strength of the potted balsa wood sheet 10 and the wind turbine blade.

[0051] However, before the vacuum injection molding process of wind turbine blades, it is difficult to determine by appearance whether balsa wood sheets will develop delamination and whitening defects after injection. Therefore, if defective balsa wood sheets are used directly as the core material of wind turbine blades, the structural strength and other parameters of the wind turbine blades will be reduced, making them unusable. Thus, the balsa wood in the wind turbine blades needs to be repaired. However, due to the large thickness of wind turbine blades, repairing the balsa wood in the wind turbine blades is difficult, costly, and will extend the production cycle of the wind turbine blades.

[0052] Therefore, the manufacturing method of balsa wood core material in some embodiments of this application, by encapsulating balsa wood sheets, allows specific defective parts of the balsa wood sheets to be exposed, thereby enabling the defective parts to be removed, which is beneficial to improving the structural strength and production efficiency of wind turbine blades and reducing the manufacturing cost of wind turbine blades.

[0053] In addition, by forming a potting layer 12 on the outer surface of the balsa wood sheet 11, the balsa wood core material can be prevented from absorbing moisture during subsequent storage to a certain extent, which is beneficial to improving the forming efficiency of wind turbine blades.

[0054] It should be noted that, based on the conditions of the balsa wood sheet 11 provided in step S1 (such as moisture content and deterioration), the potting balsa wood sheet 10 prepared in step S2 may or may not have specific defective portions 13. Figure 2 The potted balsa wood sheet 10 in the illustration is merely a representation of a potted balsa wood sheet 10 with a specific defect portion 13, and should not be construed as a limitation of this application. When the potted balsa wood sheet 10 does not have the specific defect portion 13, the potted balsa wood sheet 10 serves as the balsa wood core material; in other words, the potted balsa wood sheet 10 can be directly used as the core structure of wind turbine blades.

[0055] In step S3, specific defective portions of the potting balsa wood sheet are removed, and repair holes are formed.

[0056] Please see Figure 3 , Figure 3 for Figure 1A schematic diagram of the structure of the potted balsa wood sheet 10 after removing the specific defect portion obtained in step S3; the specific defect portion 13 of the potted balsa wood sheet 10 is removed to form a maintenance hole 14, for example, by removing the specific defect portion 13 by a drilling machine or punching equipment to form a maintenance hole 14.

[0057] In step S4, the repair hole is filled to produce balsa wood core material.

[0058] Please see Figure 4 , Figure 4 for Figure 1 A schematic diagram of the structure of the balsa core material 1 obtained in step S4. The balsa core material 1 includes a potted balsa sheet 10 with a maintenance hole 14 and a repair block 20.

[0059] Thus, the method first encapsulates the balsa wood sheet 10 to expose the specific defect portion 13 of the balsa wood sheet 10, then removes the specific defect portion 13 and fills the formed repair hole 14, thereby avoiding the occurrence of specific defects in the balsa wood core material manufactured based on this manufacturing method, which is beneficial to improving the structural strength and mechanical properties of the balsa wood core material.

[0060] Please see Figure 5 , Figure 5 This is a flowchart illustrating another method for manufacturing balsa wood core material according to some embodiments of this application. Step S4 includes steps S41 and S42.

[0061] In step S41, the prepared potting balsa wood sheet is cut to obtain a repair block without specific defects; the shape of the repair block is adapted to the repair hole.

[0062] It should be noted that some embodiments of this application do not limit the source of the spare potting balsa wood sheets. In some embodiments, the spare potting balsa wood sheets may be the potting balsa wood sheets prepared in step S2. In some embodiments, the spare potting balsa wood sheets may also be obtained from other sources.

[0063] In step S42, the repair block is installed into the maintenance hole.

[0064] It is understood that the repair block 20 and the potted balsa wood sheet 10 have undergone the same potting treatment, and the two have the same or similar resin impregnation state, dimensional consistency (such as thickness) and internal stress state. Therefore, by installing the repair block 20 into the maintenance hole 14, the reduction in structural strength and mechanical properties caused by material or state differences can be avoided to a certain extent.

[0065] For example, such as Figure 4As shown, the repair block 20 is bonded and fixed to the wall of the maintenance hole 14 with adhesive. This improves the reliability of the connection between the repair block 20 and the wall of the maintenance hole 14, thereby improving the structural strength of the balsa core material 1.

[0066] For example, the adhesive is white glue and / or epoxy glue.

[0067] Please see Figure 6 , Figure 6 This is a flowchart illustrating another method for manufacturing balsa wood core material according to some embodiments of this application. After step S1 and before step S2, the method for manufacturing balsa wood core material further includes step S1A.

[0068] In step S1A, the balsa wood sheets are dried.

[0069] Thus, before potting the balsa wood sheet 11, the balsa wood sheet 11 is first dried, which can reduce the moisture content of the balsa wood sheet 11, thereby reducing the probability of specific defective parts 13 appearing in the potted balsa wood sheet 10, reducing material waste, and improving the structural strength of the balsa wood core 1.

[0070] For example, the moisture content of the balsa wood sheet 11 after drying is less than or equal to 10%. Preferably, the moisture content of the balsa wood sheet 11 after drying is less than or equal to 4%. This can further reduce the probability of specific defective portions 13 appearing in the potted balsa wood sheet 10, reduce material waste, and help improve the structural strength of the balsa wood core 1.

[0071] Please see Figure 7 , Figure 7 This is a flowchart illustrating another method for manufacturing balsa wood core material according to some embodiments of this application. After step S1 and before step S1A, the method for manufacturing balsa wood core material further includes step S1B.

[0072] In step S1B, the surface of the balsa wood sheet is sanded.

[0073] Thus, sanding the surface of the balsa wood sheet 11 helps to improve the smoothness of the surface of the balsa wood sheet 11, which is beneficial for forming a thinner potting layer 12 on the surface of the balsa wood sheet 11 in the subsequent potting process.

[0074] Please see Figure 8 , Figure 8 A flowchart of another method for manufacturing balsa wood core material provided in some embodiments of this application; step S2 includes: steps S21 to S25.

[0075] In step S21, the first demolding structure, the balsa wood sheet, and the second demolding structure are stacked sequentially and placed between the first seal and the second seal; a receiving space is defined between the first seal and the second seal, and the first demolding structure, the balsa wood sheet, and the second demolding structure are located in the receiving space.

[0076] In some embodiments, both the first and second demolding structures include a release cloth. Thus, the release cloth can roughen the surface of the potting balsa wood sheet 10, which helps improve the adhesion between the potting balsa wood sheet 10 and the potting material during the wind turbine blade injection molding process.

[0077] In some embodiments, both the first and second demolding structures include a flow guide, which is stacked with a demolding cloth and located on the side of the demolding cloth opposite to the balsa wood sheet. The flow guide can guide the potting material to a certain extent, allowing the potting material to fully impregnate the balsa wood sheet 11.

[0078] In step S22, the containment space is evacuated.

[0079] In step S23, potting material is injected into the receiving space.

[0080] In step S24, the potting material is cured to form a potting layer.

[0081] In step S25, the first demolding structure, the second demolding structure, the first seal, and the second seal are removed.

[0082] It is understood that the process of potting the balsa wood sheet 11 in some embodiments of this application (such as steps S21 to S25) is the same as the vacuum injection molding process of wind turbine blades. In this way, a thin potting layer 12 (such as the thickness of the potting layer 12 < 0.1 mm) can be formed on the surface of the balsa wood sheet 11, which makes it easier to distinguish specific defective parts 13 from the potted balsa wood sheet 10, and also makes it easier to perform grooving and drilling and other processing on the potted balsa wood sheet 10.

[0083] Please see Figure 9 , Figure 9 for Figure 8 A schematic diagram of the potting system 100 used in steps S21 to S25 is shown below. The following will be combined with... Figure 9 The potting system 100 and the steps for potting using the potting system 100 are described in detail.

[0084] The potting system 100 includes a first demolding structure 110, a second demolding structure 120, a first seal 130, and a second seal 140. Both the first demolding structure 110 and the second demolding structure 120 include a demolding cloth 111 and a flow guide 112.

[0085] One of the first sealing element 130 and the second sealing element 140 is a filling platform, and the other of the first sealing element 130 and the second sealing element 140 is a vacuum bag film. During the filling process, the vacuum bag film is placed over the filling platform to define a receiving space 100a. For example, the filling system 100 also includes a sealing strip 170. During the filling process, the empty bag film cover and the filling platform are sealed together by the sealing strip 170, thus defining a sealed receiving space 100a between the empty bag film cover and the filling platform. The balsa wood sheet 11, the release fabrics 111 on the upper and lower sides, and the flow guide 112 are located within the receiving space 100a.

[0086] For example, the potting system 100 also includes an injection port 150, an extraction port 160, a guide tube 180, and a venting tube 190. During the potting process, both the injection port 150 and the extraction port 160 are connected to the receiving space 100a. The guide tube 180 is connected to the injection port 150, and the venting tube 190 is connected to the extraction port 160.

[0087] It should be noted that the glue injection port 150 and the air extraction port 160 can be openings made on the vacuum bag film, or the glue injection port 150 and the air extraction port 160 can be interface parts with a communicating structure. This application does not limit them in this regard.

[0088] The steps of potting using the potting system 100 include steps S100 to S1000.

[0089] In step S100, a release agent is applied to the injection platform.

[0090] In step S200, a release cloth is laid on the injection platform at the position corresponding to the release machine.

[0091] In some embodiments, the release cloth 111 may be made of nylon or polyester.

[0092] In some embodiments, a flow guide 112 is pre-laid under the release cloth 111.

[0093] In step S300, dried balsa wood sheets are laid on the release cloth.

[0094] In step S400, a release cloth is laid on the balsa wood sheet.

[0095] In this way, the release cloth can create a rough surface on the upper and lower surfaces of the potting balsa wood sheet 10, which is beneficial to improving the bonding performance between the potting balsa wood sheet 10 and the potting material during the wind turbine blade injection molding process.

[0096] For example, a flow guide 112 can be placed on top of the release fabric 111. For example, the flow guide 112 can be a flow guide net or a dense mesh net.

[0097] For example, the flow guide 112 is stacked with the release cloth 111, and the flow guide 112 is located on the side of the release cloth 111 opposite to the balsa wood sheet 11. The flow guide 112 can guide the potting material to a certain extent, so that the potting material can fully impregnate the balsa wood sheet 11.

[0098] In step S500, a vacuum bag film is placed on the filling platform, and a receiving space is defined between the empty bag film and the filling platform.

[0099] For example, the vacuum bag film cover and the filling platform are sealed together by a sealing strip 170 to define a sealed receiving space 100a between the vacuum bag film cover and the filling platform. The balsa wood sheet 11, the release cloth 111 on the upper and lower sides and the flow guide 112 are located in the receiving space 100a.

[0100] In some embodiments, the vacuum bag film may be replaced with a silicone mold.

[0101] In step S600, an injection port, a guide tube, an air extraction port, and an air guide tube are provided; both the injection port and the air extraction port are connected to the receiving space.

[0102] In step S700, the containment space is evacuated through the guide tube and the air extraction port.

[0103] In step S800, potting material is injected into the receiving space through the guide tube and the injection port.

[0104] In some embodiments, the potting material enters the injection port 150 through the guide tube 180 and is injected into the receiving space 100a under vacuum negative pressure. In the receiving space 100a, the potting material flows along the upper and lower surfaces of the balsa sheet 11, impregnating the entire balsa sheet 11.

[0105] In some embodiments, the potting material (i.e., the material of the potting layer 12) is a resin material; for example, the resin material may be one or more of epoxy resin, unsaturated polyester resin, vinyl resin, polyurethane resin, cyclopentadiene resin, and acrylic resin.

[0106] In some embodiments, the potting material may be the same resin system as the potting material used in the injection molding of the wind turbine blade, in order to improve the bonding performance between the balsa core 1 and the potting material interface, and further improve the reliability of the wind turbine blade.

[0107] In step S900, the potting material is cured.

[0108] For example, when the potting material is resin, the curing process can include: heat curing, light curing, room temperature curing, etc.

[0109] In step S1000, the release cloth, flow guide and other structures are removed to obtain potted balsa wood sheets.

[0110] Please see Figure 10 , Figure 10 This is a flowchart illustrating another method for manufacturing balsa wood core material according to some embodiments of this application. After step S4, the method for manufacturing balsa wood core material further includes step S5.

[0111] In step S5, a conformal groove is formed on one side surface of the balsa core material in the thickness direction.

[0112] It is understandable that the conformal groove allows the balsa core material 1 to be bent into the desired contour. That is, the balsa core material 1 can be used as the core material contour plate for wind turbine blades, and for the production of the shell and web of wind turbine blades. In this way, the application scenarios of the balsa core material 1 can be enriched.

[0113] Please see Figure 11 , Figure 11 for Figure 10 A schematic diagram of the structure of the balsa wood core material 1 with the conformal groove 15 obtained in step S5.

[0114] A conformal groove 15 is provided on one surface of the balsa core material 1 along the third direction Z. The conformal groove 15 includes a plurality of first conformal grooves 151 and / or a plurality of second conformal grooves 152. The plurality of first conformal grooves 151 are parallel to each other and spaced apart along the first direction X; the plurality of second conformal grooves 152 are parallel to each other and spaced apart along the second direction Y. The first direction X intersects the second direction Y, and the first direction X intersects the third direction Z.

[0115] It is understandable that during the manufacturing process of wind turbine blades, the conformal groove 15 is filled with resin. After the resin is cured, it can further strengthen the balsa wood core material 1, thereby improving the structural strength and mechanical properties of the wind turbine blades.

[0116] In some embodiments, such as Figure 11As shown, the balsa core 1 also includes a mesh fabric 16. The mesh fabric 16 is applied to one side of the balsa core 1 in the thickness direction. The mesh fabric 16 can prevent the balsa core 1 from breaking when it is bent into shape, and can further improve the reliability of the connection between the repair block 20 and the potted balsa sheet 10.

[0117] Some embodiments of this application also provide a method for manufacturing a wind turbine blade, wherein the method for manufacturing the wind turbine blade uses balsa wood core material manufactured by the balsa wood core material manufacturing method as a core material in at least part of the above embodiments.

[0118] In some embodiments, the wind turbine blade manufacturing method uses the balsa wood core material with the aforementioned conformal groove as the core material, thereby avoiding the delamination and whitening defects in the balsa wood area of ​​the wind turbine blade.

[0119] In some embodiments, the wind turbine blade manufacturing method uses the balsa wood core material with the aforementioned conformal groove as the core material for medium-thickness ply areas or areas with high maintenance difficulty. This can reduce the probability of delamination and whitening defects in the balsa wood area to a certain extent, and is conducive to reducing the manufacturing cost and labor cost of wind turbine blades.

[0120] 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.

[0121] 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.

[0122] 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.

[0123] 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 balsa wood core material, characterized in that, include: Balsa wood sheets are available; The balsa wood sheet is potted to produce potted balsa wood sheet; wherein the potted balsa wood sheet includes balsa wood sheet and potting layer; the potting layer covers at least two surfaces of the balsa wood sheet in the thickness direction; Remove specific defective portions of the potted balsa wood sheet and form maintenance holes; The maintenance holes are filled to produce the balsa wood core.

2. The method for manufacturing balsa wood core material according to claim 1, characterized in that, The filling process for the maintenance hole includes: Cut the prepared potting balsa wood sheet to obtain a repair block without specific defects; wherein the shape of the repair block is adapted to the maintenance hole; Install the repair block into the maintenance hole.

3. The method for manufacturing balsa wood core material according to claim 2, characterized in that, The step of installing the repair block into the maintenance hole includes: The repair block is bonded and fixed to the wall of the repair hole using an adhesive.

4. The method for manufacturing balsa wood core material according to claim 3, characterized in that, The adhesive is white glue and / or epoxy glue.

5. The method for manufacturing balsa wood core material according to claim 1, characterized in that, After providing the balsa wood sheets and before performing the potting process on the balsa wood sheets to produce potted balsa wood sheets, the manufacturing method further includes: The balsa wood sheets are dried.

6. The method for manufacturing balsa wood core material according to claim 5, characterized in that, The moisture content of the balsa wood sheets after drying is less than or equal to 10%.

7. The method for manufacturing balsa wood core material according to claim 5, characterized in that, After the step of providing balsa wood sheets and before the step of drying the balsa wood sheets, the manufacturing method includes: The surface of the balsa wood sheet is sanded.

8. The method for manufacturing balsa wood core material according to claim 1, characterized in that, The process of filling the balsa wood sheets to produce filled balsa wood sheets includes: The first demolding structure, the balsa wood sheet, and the second demolding structure are stacked sequentially and placed between the first sealing member and the second sealing member; wherein, the first sealing member and the second sealing member define an accommodating space, and the first demolding structure, the balsa wood sheet, and the second demolding structure are located in the accommodating space; The containment space is evacuated; Inject potting material into the containing space; The potting material is cured to form the potting layer; Remove the first demolding structure, the second demolding structure, the first seal, and the second seal.

9. The method for manufacturing balsa wood core material according to claim 8, characterized in that, Both the first demolding structure and the second demolding structure include a demolding cloth.

10. The method for manufacturing balsa wood core material according to claim 9, characterized in that, Both the first demolding structure and the second demolding structure include a flow guide, which is stacked with the demolding cloth and located on the side of the demolding cloth opposite to the balsa wood sheet.

11. The method for manufacturing balsa wood core material according to claim 1, characterized in that, The potting layer material includes one or more of epoxy resin, unsaturated polyester resin, vinyl resin, polyurethane resin, cyclopentadiene resin, or acrylic resin.

12. The method for manufacturing balsa wood core material according to claim 1, characterized in that, After filling the repair hole to obtain the balsa wood core, the manufacturing method further includes: A conformal groove is formed on one side surface of the balsa core material in the thickness direction.

13. The method for manufacturing balsa wood core material according to any one of claims 1-12, characterized in that, The thickness of the balsa wood sheet is greater than or equal to 5 mm and less than or equal to 60 mm.

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