Composite repair assembly and method of repairing a composite material

Abstract

The application relates to a composite material repairing assembly and a composite material repairing method, wherein the composite material repairing assembly comprises: a pretreatment layer, which can be laid on a wind power blade and covers a to-be-repaired area; a pouring auxiliary material layer, which is arranged on one side of the pretreatment layer in a thickness direction of the composite material repairing assembly; a first vacuum layer, which is arranged on a side of the pouring auxiliary material layer away from the pretreatment layer, and covers the pouring auxiliary material layer; and a second vacuum layer, which is arranged on a side of the first vacuum layer away from the pretreatment layer, and has an area greater than that of the first vacuum layer. The composite material repairing assembly can improve repairing efficiency and convenience.

Description

Technical Field

[0001] This application relates to the field of wind power generation technology, and in particular to a composite material repair component and a composite material repair method. Background Technology

[0002] As the core component of wind turbine generators that converts wind energy into mechanical energy, the structural integrity and operational reliability of wind turbine blades directly affect the overall power generation efficiency and safety of the turbine. Wind turbine blades are typically made of composite materials and are often manufactured using a casting process. Their airfoil design is complex, with specific distribution patterns in thickness, twist angle, and chord length from the blade root to the tip. Therefore, when repairing blade damage, a vacuum infusion process similar to that used in manufacturing is usually employed. By creating a vacuum environment in the repair area, it ensures that the infusion material can uniformly impregnate the reinforcing material and expel air bubbles, thereby forming a high-quality repair layer.

[0003] However, in actual maintenance work, the existing vacuum bag sealing and repair method has defects. Maintenance personnel need to temporarily cut various auxiliary materials such as flow guide nets, air guide felts, and vacuum membranes on-site according to the size of the damage, and then lay and seal them one by one. The operation is cumbersome and time-consuming, and it is also highly dependent on the experience of the operators.

[0004] Therefore, there is an urgent need for a composite material repair component that can improve repair efficiency, as well as a corresponding composite material repair method. Summary of the Invention

[0005] This application provides a composite material repair component and a composite material repair method, wherein the composite material repair component can improve repair efficiency and convenience.

[0006] In a first aspect, according to embodiments of this application, a composite material repair component is proposed for use on wind turbine blades. The wind turbine blades have areas to be repaired. The composite material repair component includes: a pretreatment layer, which can be laid on the wind turbine blade and covers the area to be repaired; an injection auxiliary material layer, which is disposed on one side of the pretreatment layer in the thickness direction of the composite material repair component; a first vacuum layer, which is disposed on the side of the injection auxiliary material layer away from the pretreatment layer and covers the injection auxiliary material layer; and a second vacuum layer, which is disposed on the side of the first vacuum layer away from the pretreatment layer and has an area larger than that of the first vacuum layer.

[0007] According to one aspect of the embodiments of this application, the first vacuum layer and the second vacuum layer have the same shape, and the orthographic projection of the second vacuum layer onto the plane where the first vacuum layer is located covers the first vacuum layer.

[0008] According to one aspect of the embodiments of this application, the pretreatment layer, the infusion auxiliary material layer, the first vacuum layer and the second vacuum layer are all identical in shape; the extension dimension of the infusion auxiliary material layer in the first direction is 80cm~120cm, and the extension dimension of the infusion auxiliary material layer in the second direction is 30cm~70cm.

[0009] According to one aspect of the embodiments of this application, in a first direction, the extension dimension of the first vacuum layer is A1, and the maximum extension dimension of the injection auxiliary material layer is A2; in a second direction, the extension dimension of the first vacuum layer is B1, and the maximum extension dimension of the injection auxiliary material layer is B2; 25cm≥A1-A2≥15cm, 4cm≥B1-B2≥2cm.

[0010] According to one aspect of the embodiments of this application, in the first direction, the extension dimension of the second vacuum layer is A3, and in the second direction, the extension dimension of the second vacuum layer is B3; 4cm≥A3-A1≥2cm, 4cm≥B3-B1≥2cm.

[0011] According to one aspect of the embodiments of this application, a temporary adhesive layer is provided between at least two of the pretreatment layer, the injection auxiliary material layer, the first vacuum layer and the second vacuum layer, and the layers are bonded together by the temporary adhesive layer.

[0012] According to one aspect of the embodiments of this application, a first vacuum layer is provided with a first evacuation hole through the thickness direction, and a second vacuum layer is provided with a second evacuation hole through the thickness direction; the second vacuum layer includes an overlapping area and an edge area, and the orthographic projection of the edge area is offset from the orthographic projection of the first vacuum layer along the thickness direction, and the second evacuation hole is provided in the edge area.

[0013] According to one aspect of the embodiments of this application, the infusion auxiliary material layer includes a plurality of sub-layers along the direction from the pretreatment layer to the first vacuum layer, and the plurality of sub-layers include a flow guide mesh, a porous membrane and an air guide felt arranged in sequence.

[0014] Secondly, according to embodiments of this application, a composite material repair method is proposed, applied to wind turbine blades. The wind turbine blades have areas to be repaired. The composite material repair method includes: providing a composite material repair component as described in any embodiment of the first aspect; laying the composite material repair component onto the wind turbine blade, such that the orthogonal projection of the injection auxiliary material layer on the wind turbine blade covers the area to be repaired; forming an injection channel and an air extraction channel on the side of the injection auxiliary material layer away from the wind turbine blade; connecting and sealing the edges of the first vacuum layer and the second vacuum layer to the wind turbine blade respectively; providing a vacuum pump, connecting the vacuum pump to the air extraction channel, and forming a negative pressure environment within the first vacuum layer and the second vacuum layer; providing an injection material, allowing the injection material to flow into the area to be repaired through the injection channel to form a repair substrate; and curing the repair substrate to shape it.

[0015] According to one aspect of the embodiments of this application, the step of providing a composite material repair assembly in any embodiment of the first aspect includes: providing a plurality of composite material repair assemblies; the step of laying the composite material repair assembly onto a wind turbine blade includes: overlapping the injection auxiliary layer of one of two adjacent composite material repair assemblies with the injection auxiliary layer of the other, and / or overlapping the second vacuum layer of one of two adjacent composite material repair assemblies with the second vacuum layer of the other.

[0016] According to one aspect of the present application, the step of forming an injection channel and an extraction channel on the side of the injection auxiliary material layer away from the wind turbine blade includes: making the injection channel include an interconnected injection flow channel and a connecting pipe, the injection flow channel extending along a first direction, in the first direction, making the minimum distance between the end of the injection flow channel and the opposite two sides of the injection auxiliary material layer 2cm~4cm, along a second direction, making the injection flow channel flush with the edge of the injection auxiliary material layer, and making the distance between the injection flow channel and the edge of the first vacuum layer 1cm~3cm, the first direction, the second direction and the thickness direction of the pretreatment layer intersect each other.

[0017] This application provides a composite material repair component, which includes a pretreatment layer, an injection auxiliary material layer, and two vacuum layers stacked sequentially. That is, the component includes multiple repair-required layer structures that have been pre-cut and stacked in sequence. When it is necessary to repair the blade, the component can be directly laid on the area to be repaired, which can save the steps of cutting auxiliary materials such as guide nets on site and forming vacuum membranes, effectively improving repair efficiency. Attached Figure Description

[0018] The features, advantages, and technical effects of exemplary embodiments of this application will now be described with reference to the accompanying drawings.

[0019] Figure 1 This is a schematic diagram of the structure of a composite material repair component provided in one embodiment of this application; Figure 2 This is a usage diagram of a composite material repair component provided in one embodiment of this application; Figure 3 This is a flowchart of a composite material repair method provided in one embodiment of this application; Figure 4 This is a flowchart of a composite material repair method provided in another embodiment of this application.

[0020] In the accompanying drawings, the same parts use the same reference numerals. The drawings are not drawn to scale.

[0021] in: 100 - Composite material repair component; 101 - Area to be repaired; 10 - Pretreatment layer; 20 - Injection auxiliary material layer; 30 - First vacuum layer; 40 - Second vacuum layer; 50 - Injection channel; 60 - Evacuation channel; 21-Sublayer; 51-Injection channel; 52-Connecting pipeline; X - First direction; Y - Second direction; Z - Thickness direction. Detailed Implementation

[0022] The features and exemplary embodiments of various aspects of this application will now be described in detail. Numerous specific details are set forth in the following detailed description to provide a comprehensive understanding of this application. However, it will be apparent to those skilled in the art that this application can be implemented without requiring some of these specific details. The following description of embodiments is merely intended to provide a better understanding of this application by illustrating examples. In the accompanying drawings and the following description, at least some well-known structures and techniques are not shown to avoid unnecessarily obscuring the application; and, for clarity, the dimensions of some structures may be exaggerated. Furthermore, the features, structures, or characteristics described below can be combined in any suitable manner in one or more embodiments.

[0023] The directional terms used in the following description refer to the directions shown in the figures and are not intended to limit the specific structure of the molding die and molding method of this application. It should also be noted that, unless otherwise explicitly specified and limited, "multiple" means two or more, and the terms "installation" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection. The terms "upper," "lower," "left," "right," "inner," and "outer," etc., indicating orientation or positional relationships, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0024] Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Those skilled in the art will understand the specific meaning of these terms in this application based on the specific circumstances.

[0025] As the core component of wind turbine generators that converts wind energy into mechanical energy, the structural integrity and operational reliability of wind turbine blades directly affect the power generation efficiency and safety of the entire unit. Existing blades are usually made of composite materials and manufactured through resin injection molding. Their airfoil designs are complex, with specific distribution patterns in thickness, twist angle, and chord length from the blade root to the tip.

[0026] During the transportation, hoisting, and long-term outdoor operation of wind turbine blades, damage to the blade surface or internal structure may occur due to factors such as accidental impacts, manufacturing defects, material fatigue, or extreme weather. To ensure the continuous and stable operation of wind turbines, timely and effective repair of this damage is essential. For existing repairs of composite blades, vacuum bag repair is a commonly used method with good reliability. By setting up a vacuum bag in the repair area to create a small-scale vacuum environment, it ensures that the resin uniformly impregnates the reinforcing material and removes air bubbles, thereby forming a high-quality repair layer.

[0027] However, in actual maintenance operations, especially at high-altitude locations or under severe weather conditions, existing repair methods have many shortcomings: First, maintenance personnel need to temporarily cut various infusion auxiliary materials such as guide nets, air-guiding felts, and vacuum membranes on-site according to the size of the damage, and then seal them to create a vacuum environment after laying them one by one. This process is highly dependent on the experience of the operators and is time-consuming and inefficient. Second, the sealing quality of vacuum bags made manually on-site is difficult to guarantee. Any tiny wrinkles, damage, or poor adhesion may lead to air leakage, making it impossible to achieve the required vacuum level, resulting in infusion failure, rework, or even exacerbating blade damage.

[0028] The aforementioned shortcomings result in low efficiency of existing repair methods and a high risk of repair failure.

[0029] To address the aforementioned issues, this application provides a composite material repair component and a composite material repair method, which can effectively improve repair efficiency and convenience.

[0030] It is understood that the following embodiments of this application are only used as examples of applying the repair component and repair method to the maintenance of wind turbine blades. However, it should be understood that the composite material repair component and composite material repair method provided in the embodiments of this application are not limited to the following embodiments, and can also be used in other occasions where it is necessary to repair and protect workpieces made of composite materials by injection molding.

[0031] To better understand this application, the following will be combined with... Figures 1 to 4 The composite material repair components and composite material repair methods provided in the embodiments of this application are described in detail.

[0032] Please refer to the following: Figure 1 and Figure 2 , Figure 1 This is a schematic diagram of the structure of a composite material repair component provided in one embodiment of this application. Figure 2 This is a diagram showing the usage status of a composite material repair component provided in one embodiment of this application.

[0033] In a first aspect, according to an embodiment of this application, a composite material repair component 100 is proposed for use on a wind turbine blade. The wind turbine blade has a repairable area 101. The composite material repair component 100 includes: a pretreatment layer 10, which can be laid on the wind turbine blade and covers the repairable area; an injection auxiliary material layer 20, which is disposed on one side of the pretreatment layer 10 in the thickness direction Z of the composite material repair component 100; a first vacuum layer 30, which is disposed on the side of the injection auxiliary material layer 20 away from the pretreatment layer 10 and covers the injection auxiliary material layer 20; and a second vacuum layer 40, which is disposed on the side of the first vacuum layer 30 away from the pretreatment layer 10 and has an area larger than that of the first vacuum layer 30.

[0034] This application provides a composite material repair component 100, which is used for repairing damage to wind turbine blades. Specifically, it can be used in the process of repairing wind turbine blades through resin injection molding, where the area of ​​the wind turbine blade that needs to be repaired is designated as the repair area 101.

[0035] The composite material repair assembly 100 (hereinafter referred to as the repair assembly 100) includes a pretreatment layer 10, an injection auxiliary material layer 20, a first vacuum layer 30, and a second vacuum layer 40 arranged sequentially along the thickness direction Z. The pretreatment layer 10 can be laid on the wind turbine blade and cover the area to be repaired. For example, the pretreatment layer 10 can be at least one layer of wax paper. This wax paper is laid on the surface of the composite material in the area to be repaired on the blade. Its function is to serve as a release layer during subsequent resin injection, preventing unnecessary adhesion between the injection material and the blade body or other functional layers, and ensuring that the repair assembly 100 can be smoothly peeled off from the blade surface after repair.

[0036] Understandably, after the repair is completed and the auxiliary material layer 20 and vacuum layer are removed, the pretreatment layer 10 can be temporarily left on the surface of the workpiece as a protective layer. It can be removed when the blade needs to be put into operation or installed on the hub, thereby further improving the reliability of the repaired blade.

[0037] The injection auxiliary material layer 20 is disposed on one side of the pretreatment layer 10 in the thickness direction Z of the repair component 100, that is, the injection auxiliary material layer 20 is disposed above the pretreatment layer 10, and can be optionally stacked. This injection auxiliary material layer 20 is the core part that forms the resin flow and air guiding channel, and can include a multi-layer structure. These structures can be auxiliary materials commonly used in injection molding processes, such as flow guide nets, release cloths, etc. This application does not make specific limitations on them, and can be selected according to the specific injection process and injection material type.

[0038] The first vacuum layer 30 is disposed on the side of the infusion auxiliary material layer 20 opposite to the pretreatment layer 10, that is, covering the top of the infusion auxiliary material layer 20. The first vacuum layer 30 covers the infusion auxiliary material layer 20. In the embodiments of this application, the first vacuum layer 30 can be a flexible vacuum film, the area of ​​which can be slightly larger than the infusion auxiliary material layer 20 so as to completely cover it and form a negative pressure environment before infusion.

[0039] Similar to the first vacuum layer 30, the second vacuum layer 40 is disposed on the side of the first vacuum layer 30 facing away from the pretreatment layer 10, i.e., covering the first vacuum layer 30. The area of ​​the second vacuum layer 40 can be larger than the area of ​​the first vacuum layer 30 so that it can cover at least a portion of the first vacuum layer 30 underneath. In this embodiment, the material of the second vacuum layer 40 can be the same as that of the first vacuum layer 30 to reduce costs. The edges of the second vacuum layer 40 can extend outward so that it can enclose the entire first vacuum layer 30 and its edge sealing structure.

[0040] By setting a second vacuum layer 40 with a larger area, a redundant vacuum protection layer can be formed outside the first vacuum layer 30. If a minor leak occurs in the first vacuum layer 30 during the evacuation process, the second vacuum layer 40 can maintain the vacuum level inside the entire repair system, reducing the possibility of repair failure and effectively improving the reliability and fault tolerance of the seal.

[0041] The repair component 100 in this embodiment includes most of the membrane material that needs to be laid to the area 101 to be repaired when repairing the blade. The membrane material has been pre-cut, shaped and pre-layered. When using the repair component 100 to repair the blade, a portion of the repair component 100 can be directly taken out and laid on the blade, eliminating the steps of cutting and injecting auxiliary materials on site and making vacuum bags on site, thereby effectively improving the repair efficiency.

[0042] In some alternative embodiments, the first vacuum layer 30 and the second vacuum layer 40 have the same shape, and the orthographic projection of the second vacuum layer 40 onto the plane containing the first vacuum layer 30 covers the first vacuum layer 30.

[0043] Optionally, the first vacuum layer 30 and the second vacuum layer 40 may have the same shape, such as being rectangular, circular, elliptical, waist-shaped or polygonal, etc., and may further be rectangular to facilitate manufacturing and use.

[0044] Based on this, the orthographic projection of the second vacuum layer 40 onto the plane containing the first vacuum layer 30 can cover the first vacuum layer 30. That is, when viewed along the thickness direction Z, the edge of the second vacuum layer 40 can extend beyond the edge of the first vacuum layer 30 or be flush with the edge of the first vacuum layer 30 in all directions, thereby ensuring that the entire area of ​​the first vacuum layer 30 and its sealing connection with the blade surface are protected by the second vacuum layer 40.

[0045] It is understood that the first vacuum layer 30 and the second vacuum layer 40 may be configured to be conformal and concentric, so that the width of the second vacuum layer 40 extending beyond the first vacuum layer 30 in each direction is the same or similar; or, the widths of the two sides of the second vacuum layer 40 extending beyond the first vacuum layer 30 may be different in a certain direction, so as to provide spare space for setting up structures such as the air extraction channel 60 in the second vacuum layer 40.

[0046] Through the above design, the second vacuum layer 40 can provide redundant vacuum while also providing secondary sealing to the edge of the sealing tape of the first vacuum layer 30, further enhancing the overall sealing performance of the repair structure formed by the repair component 100.

[0047] In some optional embodiments, the pretreatment layer 10, the infusion auxiliary material layer 20, the first vacuum layer 30 and the second vacuum layer 40 are all identical in shape; the extension dimension of the infusion auxiliary material layer 20 in the first direction X is 80cm~120cm, and the extension dimension of the infusion auxiliary material layer 20 in the second direction Y is 30cm~70cm.

[0048] Optionally, the pretreatment layer 10, the injection auxiliary material layer 20, the first vacuum layer 30, and the second vacuum layer 40 in the repair component 100 may all have the same or similar shapes, for example, they may all be rectangular, in order to improve consistency and facilitate standardized prefabrication and mass production.

[0049] As an optional specification, the extension dimension of the infusion auxiliary material layer 20 in the first direction X is 80cm~120cm, and can be further selected as 100cm. The extension dimension of the infusion auxiliary material layer 20 in the second direction Y is 30cm~70cm, and can be further selected as 50cm. This size range is optimized for the common maintenance area area of ​​wind turbine blades, ensuring sufficient maintenance coverage area while facilitating single-person operation and transportation.

[0050] Understandably, when the area to be repaired 101 is too large, multiple repair components 100 can be used simultaneously. This can be achieved by partially overlapping and connecting adjacent repair components 100, and sealing the overlap of the vacuum layer accordingly. When the area to be repaired 101 is too small, each layer of the repair component 100 can be folded to a suitable size and then laid out in the original sequence. This allows the repair component 100 to have good practicality.

[0051] The first direction X, the second direction Y, and the thickness direction Z of the repair component 100 are arranged in pairs, and can be further selected to be arranged in pairs perpendicularly. For example, when the repair component 100 is applied to a wind turbine blade, the first direction X can be selected as the length direction of the blade, and the second direction Y can be selected as the chord direction or circumferential direction of the blade.

[0052] By setting the size of the injection auxiliary material layer 20 within the aforementioned range, it can be prefabricated together with the first vacuum layer 30 and the second vacuum layer 40 into a standard-sized repair component 100. Repair personnel only need to select the appropriate component size based on the size of the damage on-site, or adapt different sized repair areas 101 by connecting multiple components in series or folding individual components. This eliminates the need for tedious on-site cutting work, and the modular design effectively shortens the operation time.

[0053] In some optional embodiments, in the first direction X, the extension dimension of the first vacuum layer 30 is A1, and the maximum extension dimension of the infusion auxiliary material layer 20 is A2; in the second direction Y, the extension dimension of the first vacuum layer 30 is B1, and the maximum extension dimension of the infusion auxiliary material layer 20 is B2; 25cm≥A1-A2≥15cm, 4cm≥B1-B2≥2cm.

[0054] As mentioned above, taking the first direction X as the length direction of the blade and the second direction Y as the width direction of the blade as an example, in the first direction X, the extension dimension of the first vacuum layer 30 is denoted as A1, and the maximum extension dimension of the infusion auxiliary material layer 20 is denoted as A2; in the second direction Y, the extension dimension of the first vacuum layer 30 is denoted as B1, and the maximum extension dimension of the infusion auxiliary material layer 20 is denoted as B2.

[0055] Based on this, the aforementioned dimensions should satisfy: 25cm≥A1-A2≥15cm, and 4cm≥B1-B2≥2cm. That is, the dimension of the first vacuum layer 30 in the first direction X is greater than the dimension of the infusion material, and the difference between the two is 15cm~25cm, for example, 20cm. Further, it can be selected that the infusion material layer 20 has a distance of 10cm between its opposite sides and the edge of the first vacuum layer 30 along the first direction X.

[0056] Similarly, the first vacuum layer 30 has a dimension in the second direction Y that is larger than the maximum dimension of the infusion material layer 20 in that direction, and the difference between the two dimensions is 2cm to 4cm, for example, 3cm.

[0057] By setting the aforementioned dimensional difference range, the difference between A1 and A2 allows sufficient space at both ends of the first vacuum layer 30 to accommodate the air extraction port and the glue injection port, while also providing an area for the vacuum tape to be applied. Furthermore, this difference enables the first vacuum layer 30 to form buffer zones at both ends along its length, helping to stabilize its internal air pressure. The difference between B1 and B2 precisely ensures that the first vacuum layer 30 can completely cover the sides of the potting auxiliary material layer 20, while avoiding excessive allowance that could cause film wrinkles and affect the sealing effect. In summary, the aforementioned dimensional constraints ensure that the vacuum membrane effectively covers the internal auxiliary material and reliably seals with the blade surface, forming a stable first vacuum space.

[0058] In some alternative embodiments, the extension dimension of the second vacuum layer 40 is A3 in the first direction X, and the extension dimension of the second vacuum layer 40 is B3 in the second direction Y; 4cm≥A3-A1≥2cm, 4cm≥B3-B1≥2cm.

[0059] Optionally, based on the aforementioned size range, the extension dimension of the second vacuum layer 40 along the first direction X is denoted as A3, and the extension dimension of the second vacuum layer 40 along the second direction Y is denoted as B3. Then, the aforementioned dimensions should satisfy: 4cm≥A3-A1≥2cm, 4cm≥B3-B1≥2cm.

[0060] Specifically, in the first direction X, the second vacuum layer 40 can extend beyond the first vacuum layer 30 by 2cm to 4cm, and more preferably 3cm; in the second direction Y, the second vacuum layer 40 can extend beyond the first vacuum layer 30 by 2cm to 4cm, and more preferably 3cm. That is, the second vacuum layer 40 can be 2cm to 4cm larger than the first vacuum layer 30 in both the length and width directions.

[0061] By limiting the aforementioned numerical range, it can be ensured that the second vacuum layer 40 can completely cover the edge sealing area of ​​the first vacuum layer 30. If the difference is too small, the tape of the second vacuum layer 40 may stick to the tape of the first vacuum layer 30, resulting in the inability to perform its independent function of secondary sealing and protection; if the difference is too large, it will cause material waste, and an excessively large film is prone to wrinkles during laying, affecting the vacuuming effect. The 2cm~4cm dimensional margin allows the edge of the second vacuum layer 40 to be firmly adhered to the blade surface and to form an independent, encircling sealing band with the edge of the first vacuum layer 30, thereby effectively improving the stability and reliability of the vacuuming process.

[0062] In some alternative embodiments, a temporary adhesive layer is provided between at least two of the pretreatment layer 10, the infusion auxiliary material layer 20, the first vacuum layer 30, and the second vacuum layer 40, and the layers are bonded together by the temporary adhesive layer.

[0063] Optionally, before using the repair component 100, the membrane materials in the component can be temporarily fixed by a temporary adhesive layer to reduce the possibility of misalignment between the membrane layers, thereby reducing the possibility of membrane damage or inconvenience in use.

[0064] For example, the aforementioned temporary adhesive layer may be selected as applying a small amount of removable adhesive to the corner position of the side surface of the potting auxiliary material layer 20 that contacts the first vacuum layer 30, and / or, providing a micro-adhesive temporary fixing film between the plurality of sub-layers 21 in the potting auxiliary material layer 20.

[0065] Therefore, when prefabricating the repair component 100, the pretreatment layer 10, the injection auxiliary material layer 20, and the first vacuum layer 30 can be temporarily fixed together in the correct order to form an integral, foldable, or rollable unit. Upon arrival at the repair site, the repair personnel only need to unfold this prefabricated unit and lay it as a whole on the area 101 to be repaired on the blade to carry out subsequent vacuum injection. This effectively simplifies on-site operations, has good error prevention and high convenience, and can reduce the possibility of incorrect or missing layers due to on-site chaos. At the same time, this temporary bonding will not hinder the relative movement and gas flow between layers during vacuuming.

[0066] In some optional embodiments, the first vacuum layer 30 is provided with a first evacuation hole through the thickness direction Z, and the second vacuum layer 40 is provided with a second evacuation hole through the thickness direction Z; the second vacuum layer includes an overlapping area and an edge area, and the orthographic projection of the edge area is offset from the orthographic projection of the first vacuum layer 30 along the thickness direction Z, and the second evacuation hole is provided in the edge area.

[0067] Optionally, the first vacuum layer 30 may be provided with a first evacuation port, and the second vacuum layer 40 may be provided with a second evacuation port. The two evacuation ports are used to evacuate the space inside the first vacuum layer 30 and the space between the first vacuum layer 30 and the second vacuum layer 40, respectively, to form a negative pressure vacuum environment required for infusion.

[0068] Based on this, the second vacuum layer 40 may include an overlapping region and an edge region, which may be arranged adjacent to each other, and the edge region may be arranged around the overlapping region. Along the thickness direction Z, the orthographic projection of the edge region is offset from the orthographic projection of the first vacuum layer 30. That is, the area of ​​the second vacuum layer 40 covering the first vacuum layer 30 is the overlapping region, while the area extending beyond the edge of the first vacuum layer 30 is the edge region.

[0069] Furthermore, the second evacuation hole on the second vacuum membrane is located in the edge area, that is, in the area where the second vacuum layer 40 is directly attached to the blade surface. By setting the second evacuation hole here, it is convenient to connect an external vacuum pump to independently evacuate the space between the second vacuum layer 40 and the first vacuum layer 30.

[0070] Furthermore, the first evacuation port is located on the first vacuum layer 30 at a position above the injection auxiliary material layer 20. By setting the second evacuation port in the aforementioned area, it can be staggered from the first evacuation port and maintain a certain distance. The two evacuation ports are set independently and do not interfere with each other, thereby achieving layered vacuuming and reducing the possibility of interference between the vacuum pipeline and the connection with the vacuum layer.

[0071] In some optional embodiments, the infusion auxiliary material layer 20 includes a plurality of sub-layers 21 along the direction from the pretreatment layer 10 to the first vacuum layer 30, and the plurality of sub-layers 21 include a flow guide mesh, a porous membrane and an air guide felt arranged in sequence.

[0072] Optionally, the infusion auxiliary material layer 20 includes multiple sub-layers 21, that is, it may include the membrane material required for multi-layer infusion. Specifically, along the direction from the pretreatment layer 10 to the first vacuum layer 30, the multiple sub-layers 21 may be sequentially a flow guide mesh, a porous membrane, and a gas guide felt.

[0073] The flow guide net can be laid on the pretreatment layer 10, i.e. wax paper. The flow guide net has a mesh structure, which can serve as a fast flow channel during injection, guiding the injection material to flow evenly and quickly in a two-dimensional plane and wet the reinforcing material below.

[0074] A porous membrane covers the flow guide net. This sub-layer 21 is a thin film with micropores, which allows the injection material grease and air to pass through, but prevents the upper air guide felt from directly contacting the resin in the flow guide net and causing contamination, that is, it can provide a barrier function.

[0075] A gas-guiding felt is laid on top of the porous membrane. This sublayer 21 is made of a highly permeable felt material. The gas-guiding felt can provide channels for gas flow during the vacuuming stage, ensuring that air in the entire space can be extracted quickly and evenly to form the required high-vacuum environment.

[0076] The combination of the aforementioned multiple sub-layers 21 can form a highly efficient resin infusion and gas venting system, and each sub-layer 21 is pre-cut and temporarily fixed according to standardized dimensions, thereby effectively ensuring the stability and reliability of maintenance quality.

[0077] Optionally, the repair assembly 100 may further include a dust bag, which encloses a receiving cavity and has an opening communicating with the receiving cavity. The opening may be equipped with a sealing strip or other structure to improve sealing. The pretreatment layer 10, the infusion auxiliary material layer 20, the first vacuum layer 30, and the second vacuum layer 40 in the repair assembly 100 may be stacked sequentially and all disposed within the receiving cavity. This dust bag improves the reliability of the repair assembly 100, reduces the possibility of damage to the membrane material due to dust interference, and makes the repair assembly 100 easy to carry.

[0078] Please see Figure 3 , Figure 3 This is a flowchart of a composite material repair method provided in one embodiment of this application.

[0079] Secondly, according to an embodiment of this application, a composite material repair method is proposed, applied to wind turbine blades, wherein the wind turbine blades have a repairable area 101, and the composite material repair method includes: S1. Provide a composite material repair assembly 100 according to any embodiment of the first aspect; S2. Lay the composite material repair component 100 onto the wind turbine blade, so that the orthogonal projection of the injection auxiliary material layer 20 on the wind turbine blade covers the area to be repaired 101. S3. An injection channel 50 and an air extraction channel 60 are formed on the side of the injection auxiliary material layer 20 away from the wind turbine blade. S4. Connect and seal the edges of the first vacuum layer 30 and the second vacuum layer 40 to the wind turbine blades respectively. S5. Provide a vacuum pump, connect the vacuum pump to the air extraction channel 60, and create a negative pressure environment in the first vacuum layer 30 and the second vacuum layer 40. S6. Provide injection material, allowing the injection material to flow into the area to be repaired 101 through the injection channel 50 to form a repair substrate; S7. Cure the repair substrate to shape it.

[0080] Optionally, this application also provides a composite material repair method for repairing wind turbine blades. This method first includes step S1 of providing a repair component 100. The size of this component can be selected based on the size of the area to be repaired 101, or the repair component 100 can be folded or otherwise processed according to the size of the area to be repaired 101.

[0081] In step S2, the repair assembly 100 is laid onto the wind turbine blade to be repaired. During this process, it is necessary to ensure that the orthographic projection of the injection auxiliary material layer 20 on the wind turbine blade can completely cover the area 101 to be repaired. At the same time, when the repair assembly 100 is unfolded, the pretreatment layer 10 can directly contact the blade surface.

[0082] In step S3, an injection channel 50 and an extraction channel 60 are formed on the side of the injection auxiliary material layer 20 facing away from the wind turbine blade. This may include installing an injection nozzle, an extraction nozzle, an injection channel, and an extraction channel at preset positions, so that they are connected to the space between the first vacuum layer 30 and the blade surface, respectively, to facilitate connection to the injection device and vacuum pump in subsequent steps.

[0083] In step S4, the edges of the first vacuum layer 30 and the second vacuum layer 40 are connected to the wind turbine blades and sealed by vacuum sealing tape. The order is to seal the first vacuum layer 30 first, and then seal the second vacuum layer 40.

[0084] In step S5, one or more vacuum pumps are provided and connected to the first and second suction ports via pipelines. The vacuum pumps are started to create a stable negative pressure environment within the first vacuum layer 30 and between the first vacuum layer 30 and the second vacuum layer 40. At this time, the vacuum gauge readings can be observed to confirm whether there is any leakage in the two vacuum spaces.

[0085] In step S6, after the vacuum level is reached, the prepared injection material is provided and introduced into the vacuum environment through the injection channel 50. Under the action of the internal and external pressure difference, the injection material quickly and evenly impregnates the fiber cloth and other reinforcing materials in the area to be repaired 101 through the guide net.

[0086] In step S7, the repair substrate formed by the injected potting material is cured at room temperature or under heating conditions until it reaches sufficient mechanical strength.

[0087] After all the aforementioned steps are completed, a removal step can be performed, that is, after curing, the vacuum is released, the entire repair component 100 is removed or the part of the repair component 100 except for the pretreatment layer 10 is removed, and the repair surface is subjected to necessary post-treatment, thus completing the entire repair process.

[0088] Repairing using the aforementioned method can eliminate the steps of on-site cutting, fabrication of auxiliary materials, and at least partial laying of auxiliary materials, thereby effectively improving repair efficiency.

[0089] The composite material repair method provided in this application has all the beneficial effects of the composite material repair component 100 provided in the first aspect above. For details, please refer to the specific description of the composite material repair component 100 in the above embodiments. This application will not repeat the details here.

[0090] Please see Figure 4 , Figure 4 This is a flowchart of a composite material repair method provided in another embodiment of this application.

[0091] In some alternative embodiments, step S1 of providing the composite material repair assembly 100 in any embodiment of the first aspect includes: S11. Provide multiple composite material repair components 100; Step S2, which involves laying the composite material repair assembly 100 onto the wind turbine blade, includes: S21, to overlap the injection layer 20 of one of two adjacent composite material repair components 100 with the injection layer 20 of the other, and / or, to overlap the second vacuum layer 40 of one of two adjacent composite material repair components 100 with the second vacuum layer 40 of the other.

[0092] Optionally, in order to accommodate the repair needs of a larger area, the repair method provided in this application embodiment can use multiple repair components 100 at the same time. That is, in step S1 of providing repair components 100, multiple repair components 100 can be provided at the same time, and these repair components 100 can be the same or different in size.

[0093] Correspondingly, in step S2, where the repair component 100 is laid onto the wind turbine blade, adjacent repair components 100 can be connected in series to overlap in order to achieve large-area coverage: For example, the injection layer 20 of one of two adjacent repair components 100 can overlap the injection layer 20 of the other. That is, the edge of the flow guide mesh of the latter component overlaps the edge of the flow guide mesh of the former component to ensure the continuity of the resin flow channel.

[0094] And / or, the second vacuum layer 40 of one of two adjacent repair components 100 may overlap the second vacuum layer 40 of the other. That is, the edge of the second vacuum membrane of the later component covers the edge of the second vacuum membrane of the earlier component and is connected with additional sealing tape to form a continuous second vacuum protective layer.

[0095] Through the aforementioned modular serial connection method, multiple standard-sized repair components 100 can be used simultaneously to flexibly meet the repair needs of various irregular or large-area damages, overcoming the limitations of single-size components.

[0096] In some optional embodiments, step S3, which involves forming an infusion channel 50 and an air extraction channel 60 on the side of the infusion auxiliary material layer 20 facing away from the wind turbine blade, includes: The infusion channel 50 includes an infusion flow channel 51 and a connecting pipe 52. The infusion flow channel 51 extends along the first direction X. In the first direction X, the minimum distance between the end of the infusion flow channel 51 and the opposite two sides of the infusion auxiliary material layer 20 is 2cm to 4cm. Along the second direction Y, the infusion flow channel 51 is flush with the edge of the infusion auxiliary material layer 20. The distance between the infusion flow channel 51 and the edge of the first vacuum layer 30 is 1cm to 3cm. The first direction X, the second direction Y and the thickness direction Z of the pretreatment layer 10 are arranged to intersect each other.

[0097] Optionally, in step S3, when setting the injection channel 50 and the evacuation channel 60, the positions of the two channels can be set according to the position of the repair component 100. Specifically, the injection channel 50 can include an interconnected injection flow channel 51 and a connecting pipe 52, through which the injection material can flow into the injection flow channel 51 and then into the injection auxiliary material layer 20. The injection flow channel 51 can extend a certain dimension along the first direction X to make the inflow and diffusion of the injection material more uniform.

[0098] Furthermore, when forming the injection channel 51, along the first direction X, the minimum distance between the end of the injection channel 51 and the opposite two edges of the injection auxiliary material layer 20 is 2cm to 4cm. For example, the two ends of the injection channel 51 are 3cm away from the left and right sides of the entire injection auxiliary material layer 20. By making the length of the injection channel 51 close to the size of the injection auxiliary material layer 20, the uniformity of the flow and wetting of the injection material can be further improved.

[0099] Optionally, along the second direction Y, the injection channel 51 can be flush with the edge of the injection auxiliary layer 20, that is, the orthogonal projection of the injection channel 51 along the thickness direction Z can at least partially coincide with the edge of the injection auxiliary layer 20. This allows the resin to be injected directly into the injection auxiliary layer 20 from one edge and spread evenly along the width direction.

[0100] Meanwhile, along the second direction Y, the distance between the injection channel 51 and the edge of the first vacuum layer 30 can be 1cm to 3cm, or more preferably about 2cm. This allows the edge of the first vacuum layer 30 to have a flat area with sufficient space for attaching vacuum tape, without being pushed up by the injection auxiliary material layer 20 or the injection channel 51 below, thereby further improving the sealing quality of the first vacuum space.

[0101] By controlling the dimensions and position as described above, the efficiency of injection and gas extraction, as well as the reliability of the seal, can be improved.

[0102] Although this application has been described with reference to preferred embodiments, various modifications can be made thereto and components can be replaced with equivalents without departing from the scope of this application. In particular, the technical features mentioned in the various embodiments can be combined in any manner, provided there is no structural conflict. This application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A composite material repair assembly for use in wind turbine blades, the wind turbine blades having areas to be repaired, characterized in that, The composite material repair assembly includes: A pretreatment layer is provided, which can be laid on the wind turbine blade and cover the area to be repaired; An infusion layer is disposed on one side of the pretreatment layer in the thickness direction of the composite material repair assembly; A first vacuum layer is disposed on the side of the infusion auxiliary material layer away from the pretreatment layer, and the first vacuum layer covers the infusion auxiliary material layer; A second vacuum layer is disposed on the side of the first vacuum layer away from the pretreatment layer, and the area of ​​the second vacuum layer is larger than the area of ​​the first vacuum layer.

2. The composite material repair assembly according to claim 1, characterized in that, The first vacuum layer and the second vacuum layer have the same shape, and the orthographic projection of the second vacuum layer onto the plane containing the first vacuum layer covers the first vacuum layer.

3. The composite material repair assembly according to claim 1, characterized in that, The pretreatment layer, the infusion auxiliary material layer, the first vacuum layer, and the second vacuum layer all have the same shape; The extension dimension of the injection auxiliary material layer in the first direction is 80cm~120cm, and the extension dimension of the injection auxiliary material layer in the second direction is 30cm~70cm.

4. The composite material repair assembly according to claim 3, characterized in that, In the first direction, the extension dimension of the first vacuum layer is A1, and the maximum extension dimension of the infusion auxiliary material layer is A2. In the second direction, the extension dimension of the first vacuum layer is B1, and the maximum extension dimension of the infusion auxiliary material layer is B2. 25cm≥A1-A2≥15cm, 4cm≥B1-B2≥2cm.

5. The composite material repair assembly according to claim 3, characterized in that, In the first direction, the extension dimension of the second vacuum layer is A3, and in the second direction, the extension dimension of the second vacuum layer is B3; 4cm≥A3-A1≥2cm, 4cm≥B3-B1≥2cm.

6. The composite material repair assembly according to claim 1, characterized in that, A temporary adhesive layer is provided between at least two of the pretreatment layer, the infusion auxiliary material layer, the first vacuum layer, and the second vacuum layer, and the layers are bonded together by the temporary adhesive layer.

7. The composite material repair assembly according to claim 1, characterized in that, The first vacuum layer has a first evacuation hole extending through it along the thickness direction, and the second vacuum layer has a second evacuation hole extending through it along the thickness direction. The second vacuum layer includes an overlapping area and an edge area. Along the thickness direction, the orthographic projection of the edge area is offset from the orthographic projection of the first vacuum layer, and the second evacuation hole is disposed in the edge area.

8. The composite material repair assembly according to claim 1, characterized in that, The infusion auxiliary material layer includes multiple sub-layers. Along the direction from the pretreatment layer to the first vacuum layer, the multiple sub-layers include a flow guide mesh, a porous membrane, and an air guide felt arranged in sequence.

9. A composite material repair method applied to wind turbine blades, wherein the wind turbine blades have areas to be repaired, characterized in that, The composite material repair method includes: Provide a composite material repair assembly as described in any one of claims 1 to 8; The composite material repair assembly is laid onto the wind turbine blade, such that the orthogonal projection of the injection auxiliary material layer on the wind turbine blade covers the area to be repaired. An injection channel and an air extraction channel are formed on the side of the injection auxiliary material layer opposite to the wind turbine blade; The edges of the first vacuum layer and the second vacuum layer are respectively connected and sealed to the wind turbine blade; A vacuum pump is provided, which is connected to the air extraction channel to create a negative pressure environment in the first vacuum layer and the second vacuum layer. A grouting material is provided and flows into the area to be repaired through the grouting channel to form a repair substrate; The repair substrate is cured to shape it.

10. The composite material repair method according to claim 9, characterized in that, The step of providing the composite material repair assembly as described in any one of claims 1 to 8 includes: Provide multiple of the aforementioned composite material repair components; The step of laying the composite material repair assembly onto the wind turbine blade includes: The injection layer of one of two adjacent composite repair assemblies overlaps with the injection layer of the other, and / or the second vacuum layer of one of two adjacent composite repair assemblies overlaps with the second vacuum layer of the other.

11. The composite material repair method according to claim 9, characterized in that, The step of forming an injection channel and an air extraction channel on the side of the injection auxiliary material layer opposite to the wind turbine blade includes: The infusion channel includes a connected infusion flow channel and a connecting pipe. The infusion flow channel extends along a first direction. In the first direction, the minimum distance between the end of the infusion flow channel and the opposite edges of the infusion auxiliary material layer is 2cm to 4cm. Along a second direction, the infusion flow channel is flush with the edge of the infusion auxiliary material layer, and the distance between the infusion flow channel and the edge of the first vacuum layer is 1cm to 3cm. The first direction, the second direction, and the thickness direction of the pretreatment layer are arranged to intersect each other.

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