Method for integrally infusion molding a wind turbine blade
By dividing the web of the wind turbine blade into two parts, the bonding corner and the main body of the web, and using a vacuum or negative pressure injection process to achieve integrated impregnation and connection, the problem of insufficient resin impregnation in the bonding corner area of the web is solved, the structural consistency and molding accuracy are improved, and the production cost and time are reduced.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-04-28
- Publication Date
- 2026-06-12
AI Technical Summary
In existing technologies, insufficient resin impregnation in the bonding angle area of the web of wind turbine blades easily leads to defects such as bubbles, air strands, and voids. Furthermore, the maintenance process is complex, affecting structural consistency and precision, resulting in low production efficiency.
The web is divided into two parts: the bonding corner and the web body. Pre-fabricated bonding corner components are prepared in advance and matched with the forming area of the web body. Integrated impregnation connection is achieved through vacuum or negative pressure injection process to ensure tight fit and synchronous curing, avoiding the defects in traditional secondary bonding process.
It improves the structural integrity and molding accuracy of the bonding corner area, reduces subsequent repair processes, shortens the manufacturing cycle, reduces material and labor consumption, and improves the overall molding quality and production efficiency of wind turbine blades.
Smart Images
Figure CN122185601A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of wind turbine blade injection molding technology, and in particular to a method for integral injection molding of wind turbine blades. Background Technology
[0002] As wind turbines develop towards higher power and larger sizes, the length of wind turbine blades is constantly increasing, and the capacity of single units is continuously improving, placing higher demands on the structural strength, fatigue performance, and manufacturing precision of the blades. The web, as the main load-bearing component inside the blade, forms a stable spatial force system with the main beam and skin, transmitting shear loads and maintaining the blade's cross-sectional shape. Its molding quality directly affects the overall mechanical properties and assembly precision of the blade. In existing technologies, wind turbine blade webs are typically constructed by layering fiberglass reinforcement materials and core materials, and then combining them with auxiliary materials through a vacuum integrated casting process. This involves simultaneously laying the web body and the web bonding angle within the same mold, and completing resin injection and curing in one step.
[0003] However, in practical applications, the aforementioned integrated injection process still has the following shortcomings: First, since the web bonding angle is usually L-shaped or T-shaped, the resin flow resistance in the corner area is relatively large, which easily forms a dead flow angle. At the same time, the venting path in this area is limited, and air is not easy to be discharged, resulting in insufficient wetting of the fiber reinforcement material, which easily produces defects such as bubbles, air strands and voids, thereby reducing the mechanical properties of the bonding angle area and making it a weak part of the structure. Second, for the poor wetting or bubble defects that have occurred in the web bonding angle, manual repair is usually required after demolding. However, the bonding angle structure is complex and the dimensional accuracy requirements are high. During the repair process, local thickness deviation and angle deviation are easily caused, reducing the structural consistency. Moreover, the repair process is time-consuming and resource-intensive. Third, since the accuracy of the web gap is difficult to guarantee, interference and collision with the skin or main beam are likely to occur during the blade mold assembly process. On-site adjustment is required, which in turn affects the dimensional accuracy of the blade structure and the internal stress distribution, and may even lead to mold failure, reducing the stability of product quality. Summary of the Invention
[0004] The purpose of this invention is to solve or at least alleviate some or all of the aforementioned problems. Therefore, the purpose of this invention is to provide a method for integral injection molding of wind turbine blades, which solves the problems of insufficient resin impregnation, air bubbles, air strands, and voids that easily occur in the bonding corner area of the web in the prior art; at the same time, it reduces dimensional deviations and uneven mechanical properties caused by later maintenance processes, improves the overall molding accuracy and structural consistency of the web; further reduces labor and material consumption in the production process, shortens the manufacturing cycle, and reduces the risk of assembly conflicts caused by excessive web gaps, thereby improving the overall molding quality and production efficiency of wind turbine blades.
[0005] To achieve this objective, the present invention adopts the following technical solution: The method for integral casting and molding of wind turbine blades includes the following steps: S1: Provide a web forming mold, including a web body forming area and bonding corner forming areas on both sides thereof; and prefabricate prefabricated bonding corner components according to the web structure design parameters, so that the geometry of the prefabricated bonding corner components matches the corresponding bonding corner forming areas; S2: The prefabricated adhesive corner component is attached and positioned on both sides of the adhesive corner forming area of the web body forming area through the positioning structure, and the fit between the prefabricated adhesive corner component and the adhesive corner forming area is less than or equal to 1mm. S3: Using the prefabricated adhesive corner member after positioning as the boundary reference, lay the main web layer on the main web forming area so that the edge of the main web layer overlaps with the side wall of the prefabricated adhesive corner member to form a continuous connection and seamless fit. The joint is manually compacted. S4: After the layup is completed, a flow-guiding injection assembly is laid on top of the main web layup according to the vacuum injection process requirements, and a vacuum film is applied to the outside of the web forming mold to vacuum seal the prefabricated adhesive corner member and the main web layup inside the web forming mold. Resin is injected into the web forming mold using the flow-guiding injection assembly under vacuum or negative pressure environment, so that the resin penetrates the interface area of the main web layup and the prefabricated adhesive corner member, thereby achieving integrated impregnation and connection of the main web layup and the prefabricated adhesive corner member. S5: The resin is cured under vacuum or negative pressure conditions to solidify the prefabricated adhesive corner member and the web body to form an integral composite material structure. S6: After curing, demold the molded web and perform surface finishing and quality inspection.
[0006] In some alternative embodiments, in step S2, before positioning the prefabricated adhesive corner member in the adhesive corner forming area, the web forming mold is cleaned and its surface is polished to remove impurities and residual adhesive, and a release agent is applied to its surface; at the same time, the surfaces of each prefabricated adhesive corner member are cleaned to remove the release agent from its surface, improve its wetting state with the web body layup during the injection molding process, and thus improve the interfacial bonding strength.
[0007] In some optional embodiments, in step S3, the outer structural layer, the core material layer and the inner structural layer are laid sequentially in the web body forming area according to a preset layup order to form the web body layup with a symmetrical structure.
[0008] In some alternative embodiments, the prefabricated adhesive corner member includes a T-shaped prefabricated block and an L-shaped prefabricated block. The T-shaped prefabricated block is disposed on one side of the main body forming area of the web plate to form an adhesive corner structure on the leeward side of the web plate, and the L-shaped prefabricated block is disposed on the other side of the main body forming area of the web plate to form an adhesive corner structure on the windward side of the web plate.
[0009] In some alternative embodiments, the positioning structure includes a pad block, and the web forming mold has a positioning groove along its length on its leeward side. The pad block and the T-shaped precast block are embedded in the positioning groove, and the geometry of the pad block matches the side of the T-shaped precast block away from the main web layer, so as to limit and support the T-shaped precast block.
[0010] In some alternative embodiments, both the T-shaped precast block and the L-shaped precast block have a radius (R-angle) on the side facing the main web layer.
[0011] In some optional embodiments, the prefabricated adhesive corner member includes a plurality of T-shaped prefabricated blocks and a plurality of L-shaped prefabricated blocks, the plurality of T-shaped prefabricated blocks and the plurality of L-shaped prefabricated blocks are arranged continuously along the length direction of the web forming mold, and the splicing joint between adjacent T-shaped prefabricated blocks or adjacent L-shaped prefabricated blocks is less than 1 mm.
[0012] In some alternative embodiments, adjacent T-shaped precast blocks and adjacent L-shaped precast blocks are connected by connectors, which are C-shaped fiber reinforced members, with both ends of the connectors spanning and connecting to adjacent T-shaped precast blocks or adjacent L-shaped precast blocks, respectively.
[0013] In some alternative embodiments, the side plates that overlap with the web body ply of the T-shaped precast block and the L-shaped precast block are provided with a sloping transition structure.
[0014] In some alternative embodiments, the flow guiding and infusion assembly includes a flow guiding net and a flow channel. The flow guiding net covers the web body ply and the flow channel is disposed above the flow guiding net along the length direction of the web forming mold and is located at the center position of the width direction of the web forming mold.
[0015] The beneficial effects of this invention are: This invention provides a method for integral injection molding of wind turbine blades. The web is divided into two parts: the bonding corner and the main body. The geometrically complex and difficult-to-control bonding corner structure is separated from the main injection system and pre-molded under controllable conditions, effectively improving the structural integrity and initial quality stability of the bonding corner area. By controlling the fit between the pre-fabricated bonding corner component and the bonding corner molding area of the web molding mold to be less than or equal to 1 mm, a tight interface is formed between the two, suppressing the formation of preferential flow channels in the resin during injection. This mechanism reduces the probability of molding defects such as bubbles, air fibers, and voids, and improves the uniformity of interface wetting. The main body web layer is laid using the positioned pre-fabricated bonding corner component as the boundary reference. The edge of the main body web layer overlaps with the sidewall of the pre-fabricated bonding corner component and is manually compacted to achieve a seamless fit. This creates a continuous transition fiber structure interface in the bonding corner area, transforming this area from a resin-bonded interface connection mode to a continuous fiber load-bearing structure. By implementing guided infusion under a total vacuum or negative pressure environment, the resin simultaneously impregnates the interface areas of the web main ply and the prefabricated bonded corner components under a unified pressure field and flow path control. This achieves synchronous impregnation and integrated molding of the interface and the main structure, avoiding the problems of insufficient impregnation and uneven performance caused by the independent formation of interfaces in traditional secondary bonding processes. Simultaneously, resin curing is completed under vacuum or negative pressure conditions, allowing the prefabricated bonded corner components and the web main ply to achieve overall curing under pressure and bonding. Based on the synergistic effect of the above steps, the problems of insufficient resin impregnation, air bubbles, air fibers, and voids in the web bonded corner areas of existing technologies can be significantly solved. It also reduces subsequent repair and secondary bonding processes, lowers dimensional deviations caused by multiple processes, and thus improves the overall molding accuracy and structural consistency of the web. Furthermore, since this invention integrates the original segmented manufacturing and post-bonding processes into an integrated injection molding process, it can effectively reduce manual operation steps and material waste, shorten the manufacturing cycle, and reduce the risk of assembly interference caused by web size deviation or gap deviation, thereby improving the overall molding quality and production efficiency of wind turbine blades. Attached Figure Description
[0016] Figure 1 This is a flowchart of the integrated injection molding method for wind turbine blades described in this invention; Figure 2 This is a schematic diagram of the structure of the web forming mold described in this invention; Figure 3 This is a schematic diagram of the splicing structure of the T-shaped prefabricated block described in this invention; Figure 4 This is a schematic diagram of the splicing structure of the L-shaped prefabricated block described in this invention.
[0017] In the picture: 1. Web forming mold; 11. Web main body forming area; 12. Bonding corner forming area; 13. Positioning groove; 14. Positioning structure; 2. T-shaped precast block; 3. L-shaped precast block; 4. R-angle; 5. Sloping transition structure; 6. Web main body layup; 61. Outer structural layer; 62. Core material layer; 63. Inner structural layer; 7. Flow guiding and injection assembly; 71. Flow guiding net; 72. Flow channel; 8. Vacuum film; 9. Sealing strip; 10. Connector. Detailed Implementation
[0018] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.
[0019] In this invention, the terms "comprising," "including," "having," or any other variations thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.
[0020] In this invention, the term "and / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent three cases: A alone, A and B simultaneously, and B alone. Additionally, in this invention, the character " / " generally indicates that the preceding and following related objects have an "and / or" relationship.
[0021] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," "fixed," "combined," "coupled," and "installed" should be interpreted broadly. For example, they can refer to a fixed connection or a detachable connection; a direct connection or an indirect connection via an intermediate medium; or the internal communication of two components or the interaction between two components. As examples, a direct connection refers to two parts or components being connected together without the need for an intermediate medium, while an indirect connection refers to two parts or components each being connected to at least one intermediate medium, with the connection achieved through the intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances. Furthermore, "connected" and "coupled" are not limited to physical or mechanical connections or couplings, but can also include electrical connections or couplings.
[0022] In this invention, those skilled in the art will understand that relative terms (e.g., “about,” “approximately,” “basically,” etc.) used in conjunction with quantities or conditions are to include the value and have the meaning indicated by the context. For example, such relative terms include at least the degree of error associated with the measurement of a particular value, tolerances associated with the particular value due to manufacturing, assembly, use, etc. Such terms should also be considered as disclosing a range defined by the absolute values of the two endpoints. Relative terms may refer to a certain percentage (e.g., 1%, 5%, 10% or more) of the indicated value. Numerical values not using relative terms should also be disclosed as specific values with tolerances. Furthermore, “basically” when expressing relative angular relationships (e.g., substantially parallel, substantially perpendicular) may refer to a certain degree (e.g., 1 degree, 5 degrees, 10 degrees or more) added to or subtracted from the indicated angle.
[0023] In this invention, those skilled in the art will understand that the function performed by a component can be performed by one component, multiple components, one part, or multiple parts. Similarly, the function performed by a part can also be performed by one part, one component, or a combination of multiple parts.
[0024] In this invention, the terms "upper," "lower," "left," "right," "front," and "rear," etc., refer to the orientations or positional relationships shown in the accompanying drawings. They are used solely for ease of description and simplification of operation, 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 invention. Furthermore, in the context, it should be understood that when an element is mentioned as being "upper" or "lower" than another element, it can be directly connected to the other element "upper" or "lower," or indirectly connected through an intermediate element. It should also be understood that directional terms such as "upper side," "lower side," "left side," "right side," "front side," and "rear side" not only represent positive orientation but can also be understood as lateral orientation. For example, "above," "on top of," "upper side of," and "above" the first feature "above" or "on the second feature" includes the first feature being directly above, to the upper left, to the upper right, to the upper front, and to the upper rear of the second feature, or simply indicating that the first feature is at a higher horizontal level than the second feature. The terms "below," "under," "below," and "below" for "first feature" and "second feature" include situations where the first feature is directly below, to the lower left, to the lower right, in front of, or behind the second feature, or simply indicate that the first feature is at a lower horizontal level than the second feature. Furthermore, the terms "first" and "second" are used merely for descriptive distinction and have no specific meaning.
[0025] Please refer to Figures 1 to 4 As shown in the figure, this embodiment provides a method for integral injection molding of wind turbine blades, including the following steps: S1: Provide a web forming mold 1, including a web main forming area 11 and bonding corner forming areas 12 located on both sides thereon; and prefabricate prefabricated bonding corner components according to the web structure design parameters, so that the geometry of the prefabricated bonding corner components matches the corresponding bonding corner forming areas 12. S2: The prefabricated adhesive corner component is attached and positioned on the adhesive corner forming area 12 on both sides of the web body forming area 11 through the positioning structure 14, and the fit between the prefabricated adhesive corner component and the adhesive corner forming area 12 is less than or equal to 1mm. S3: Using the prefabricated adhesive corner component after positioning as the boundary reference, the main web layer 6 is laid on the main web forming area 11, so that the edge of the main web layer 6 overlaps with the side wall of the prefabricated adhesive corner component to form a continuous connection and seamless fit. The joint is manually compacted. S4: After the layup is completed, the flow guiding and injection assembly 7 is laid on the web main layup 6 according to the vacuum injection process requirements, and a vacuum film 8 is applied to the outside of the web forming mold 1 to perform overall vacuum sealing of the prefabricated adhesive corner component and the web main layup 6 in the web forming mold 1. Resin is injected into the web forming mold 1 using the flow guiding and injection assembly 7 under vacuum or negative pressure environment, so that the resin penetrates the interface area of the web main layup 6 and the prefabricated adhesive corner component, thereby realizing the integrated impregnation connection of the web main layup 6 and the prefabricated adhesive corner component. S5: The resin is cured under vacuum or negative pressure conditions to cure the prefabricated bonded corner components and the web body layup 6 to form an integral composite material structure. S6: After curing, demold the molded web and perform surface finishing and quality inspection.
[0026] This method divides the web into two parts: the bonding corner and the main body of the web. Since the bonding corner has a complex geometry, it is difficult to guarantee the quality of layup and wetting. Therefore, the geometrically complex and difficult-to-control bonding corner structure is transferred to a pre-formed state under controllable conditions. The difficult-to-wet area is separated from the main grouting system, which can effectively improve the structural integrity and initial quality stability of the bonding corner area, reduce structural defects caused by uneven layup on site, and no longer rely on on-site layup and grouting.
[0027] By controlling the fit between the prefabricated adhesive corner component and the adhesive corner forming area 12 of the web forming mold 1 to be less than or equal to 1 mm, a tight fit interface is formed between the two, avoiding the formation of local gaps or closed cavities. This inhibits the formation of preferential flow channels in the resin during the pouring process, reduces the space for air retention, and thus reduces the probability of forming defects such as bubbles, air strands and voids, thereby improving the uniformity of interface wetting.
[0028] The web main layup 6 is laid with the pre-fabricated adhesive corner component as the boundary reference, and the edge of the web main layup 6 overlaps with the side wall of the pre-fabricated adhesive corner component and is compacted by hand to achieve seamless bonding. This creates a continuous transition fiber structure interface in the adhesive corner area, transforming the interface connection mode of this area from resin bonding to a continuous fiber load-bearing structure. This not only helps to improve the interface bonding strength, but also removes local air and increases the fiber volume fraction before injection, thereby further improving the resin impregnation conditions.
[0029] Based on this, by implementing guided injection under a general vacuum or negative pressure environment, the resin can simultaneously impregnate the interface area of the web main layup 6 and the prefabricated adhesive corner component under a unified pressure field and flow path control, thereby achieving synchronous impregnation and integrated molding of the interface and the main structure, avoiding the problems of insufficient impregnation and uneven performance caused by the independent formation of the interface in the traditional secondary bonding process.
[0030] Meanwhile, resin curing is completed under vacuum or negative pressure conditions, so that the prefabricated adhesive corner components and the main web layer 6 are cured as a whole under pressure and bonding, effectively preventing interface rebound or gas backflow during the curing process, thereby further improving the interface density and structural consistency, and making the mechanical properties of the adhesive corner area tend to be consistent with the main structure.
[0031] Based on the synergistic effect of the above steps, this embodiment can significantly solve the problems of insufficient resin impregnation, air bubbles, air strands, and voids that easily occur in the bonding corner area of the web in the prior art. At the same time, it reduces the number of subsequent repair and secondary bonding processes, and reduces the dimensional deviation caused by the superposition of multiple processes, thereby improving the overall molding accuracy and structural consistency of the web. In addition, since this embodiment integrates the original segmented manufacturing and subsequent bonding processes into an integrated injection molding process, it can effectively reduce manual operation links and material waste, shorten the manufacturing cycle, and reduce the risk of assembly interference caused by web dimensional deviations or gap deviations, thereby improving the overall molding quality and production efficiency of wind turbine blades.
[0032] Specifically, the vacuum film 8 is preferably a high-toughness vacuum film 8, whose edge is sealed to the periphery of the web forming mold 1 through the sealing strip 9, thereby ensuring the overall vacuum sealing performance of the high-toughness vacuum film 8 and the negative pressure stability during the injection process.
[0033] Furthermore, in step S2, before positioning the prefabricated bonded corner components in the bonded corner molding area 12, the web molding mold 1 is cleaned and its surface is polished to remove impurities and residual adhesive, and a release agent is applied to its surface; this ensures the demolding stability and surface quality of the part during the molding process. Simultaneously, the surfaces of each prefabricated bonded corner component are cleaned to remove the release agent, improve its wetting state with the web main layup 6 during the injection molding process, and thus enhance the interfacial bonding strength. Since release agents typically have low surface energy, if they remain on the surface of the prefabricated component, they can easily form an isolation layer at the interface, reducing the resin's wetting ability at that interface and thus affecting the resin's wetting effect on the fiber material. Through the above surface cleaning treatment, the interfacial activity of the prefabricated bonded corner component surface can be effectively restored, improving the resin's spreading ability and interfacial penetration ability during the injection process, allowing the resin to more fully wet the interfacial area between the web main layup 6 and the prefabricated bonded corner component, thereby enhancing the interfacial bonding strength and reducing defects such as bubbles and voids.
[0034] In some embodiments, in step S3, the outer structural layer 61, the core material layer 62, and the inner structural layer 63 are sequentially laid in the web body forming area 11 according to a preset layup sequence to form a web body layup 6 with a symmetrical structure. This allows the shrinkage strain of the upper and lower layers of the web body to be balanced during the curing process, reducing warping deformation caused by differences in curing shrinkage and improving structural dimensional stability. Simultaneously, it ensures a balanced stress distribution on the upper and lower surfaces of the web under bending loads, which is beneficial for improving overall bending stiffness and fatigue performance. Furthermore, the symmetrical structure also allows for a more uniform distribution of resin penetration resistance along the thickness direction during injection, thereby improving resin flow uniformity and wetting consistency, and reducing the risk of poor local wetting and defects.
[0035] like Figure 2As shown, in some embodiments, the prefabricated adhesive corner member includes a T-shaped prefabricated block 2 and an L-shaped prefabricated block 3. The T-shaped prefabricated block 2 is disposed on one side of the web body forming area 11 to form an adhesive corner structure on the leeward side of the web. The L-shaped prefabricated block 3 is disposed on the other side of the web body forming area 11 to form an adhesive corner structure on the windward side of the web. In this design, T-shaped precast blocks 2 are laid on the bonding corner molding area 12 on the leeward side of the web molding mold 1, while L-shaped precast blocks 3 are laid on the bonding corner molding area 12 on the windward side of the web molding mold 1. By using precast blocks with different structures, the bonding corner area on the leeward side utilizes T-shaped precast blocks 2 with vertically extending structures to increase the interface contact area and improve the structure's anti-peeling ability, thus adapting to the stress characteristics of the leeward side, which is prone to tensile and peeling loads during operation. Simultaneously, the relatively simplified L-shaped precast blocks 3 are used on the windward side, which, while meeting the structural connection strength requirements, helps reduce material usage and improve resin injection flow conditions, thereby enhancing molding stability. Therefore, by setting precast bonding corner components with different structural forms on both sides of the web, the synergistic optimization of structural performance and molding process is achieved, contributing to improving the overall mechanical properties and manufacturing quality of the web.
[0036] Since the T-shaped precast block 2 is more difficult to position than the L-shaped precast block 3, in order to ensure its fit with the web forming mold 1, in some embodiments, the positioning structure 14 includes a pad. The web forming mold 1 has a positioning groove 13 along its length on its leeward side. The pad and the T-shaped precast block 2 are embedded in the positioning groove 13, and the geometry of the pad matches the side of the T-shaped precast block 2 away from the web main ply 6, so as to limit and support the T-shaped precast block 2. The positioning groove 13 guides and constrains the position of the T-shaped precast block 2, and the back side is supported by the geometrically matched pad, so that the T-shaped precast block 2 is in a stable and constrained state during the plying and vacuum infusion process, thereby preventing it from shifting or deforming under the action of resin flow and negative pressure. This better maintains the fit between the T-shaped precast block 2 and the web main ply 6, reduces interface gaps, improves interface wetting quality, reduces the risk of defects such as bubbles and voids, and helps to improve the dimensional consistency and molding stability of the web structure.
[0037] Specifically, the pad can be, but is not limited to, silicone blocks; no specific limitation is made here.
[0038] To prevent wrinkling of the web main ply 6 at corners and resin stagnation or gas trapping at sharp corners, in some embodiments, the T-shaped precast block 2 and L-shaped precast block 3 are provided with an R-angle 4 on the side facing the web main ply 6. This allows the web main ply 6 to continuously adhere along the curved surface during installation, avoiding bridging or wrinkling at right angles, thereby improving ply density and reducing local voids. It also improves the resin flow during injection, creating a continuous flow path in corner areas, reducing flow resistance and gas trapping, thus improving interface wetting uniformity and reducing defects such as bubbles and voids. The R-angle 4 also reduces stress concentration in the bonding corner area, allowing for smooth load transfer between the web main ply 6 and the precast bonding corner components, thereby improving interfacial bonding strength and structural fatigue performance.
[0039] like Figure 3 and Figure 4 As shown, since the web of a wind turbine blade is typically over 10 meters long and the bonding angles are continuously distributed along the length, in order to reduce the difficulty of manufacturing the bonding angles, in some embodiments, the prefabricated bonding angle components include multiple T-shaped prefabricated blocks 2 and multiple L-shaped prefabricated blocks 3. The multiple T-shaped prefabricated blocks 2 and multiple L-shaped prefabricated blocks 3 are continuously arranged along the length direction of the web forming mold 1, and the splicing seams between adjacent T-shaped prefabricated blocks 2 or adjacent L-shaped prefabricated blocks 3 are less than 1 mm. By segmenting the prefabricated bonding angle components into multiple T-shaped prefabricated blocks 2 and multiple L-shaped prefabricated blocks 3 and arranging them continuously along the length direction, the bonding angle structure can be modularly constructed in the long dimension direction, thereby reducing the manufacturing and forming difficulty of individual components and improving the consistency of structural processing. Meanwhile, by controlling the splicing joint between adjacent precast blocks to be less than 1mm, the splicing area can be fully spanned and filled by resin during vacuum infusion, thereby avoiding the formation of independent voids or gas retention channels, realizing continuous impregnation and connection of the interface area, reducing the generation of defects such as bubbles, voids and local delamination, and helping to improve the dimensional consistency and structural continuity of the bonding corner area in the length direction.
[0040] To enhance the connection strength between adjacent precast blocks, in some embodiments, adjacent T-shaped precast blocks 2 and adjacent L-shaped precast blocks 3 are connected by connectors 10. Connectors 10 are C-shaped fiber reinforced members, with both ends of the connector 10 spanning and connecting to adjacent T-shaped precast blocks 2 or adjacent L-shaped precast blocks 3, respectively. By using C-shaped fiber reinforced members to bridge and connect adjacent precast blocks, the load transfer path is changed from the traditional resin-filled interface transfer to direct fiber reinforcement transfer, improving the load-bearing capacity and structural integrity of the splicing area.
[0041] In some embodiments, the side plates of the T-shaped precast block 2 and L-shaped precast block 3 overlapping with the web main ply 6 are provided with inclined transition structures 5, so that the geometric connection between the two changes from an abrupt form to a gradual transition form, which is conducive to the gradual bonding of the web main ply 6 on the inclined surface, avoiding bridging or wrinkling, improving the continuity and density of the ply; it can also improve the flow state of the resin during the injection process, so that the resin forms a continuous flow path along the inclined surface.
[0042] In some embodiments, the flow guiding and infusion assembly 7 includes a flow guiding net 71 and a flow channel 72. The flow guiding net 71 covers the web main body layup 6, and the flow channel 72 is disposed above the flow guiding net 71 along the length direction of the web forming mold 1 and is located at the center position in the width direction of the web forming mold 1. By setting the flow guiding net 71 and the centrally arranged flow channel 72 to cooperate, the resin is first stably transported along the length direction through the flow channel 72 during the infusion process, and then rapidly diffuses laterally under the action of the flow guiding net 71, thereby forming a flow state that advances along the length direction and is symmetrically distributed along the width direction, improving the overall wetting consistency and molding quality stability of the web main body layup 6 and the prefabricated adhesive corner components.
[0043] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.
Claims
1. A method for integral casting and molding of wind turbine blades, characterized in that, Includes the following steps: S1: Provide a web forming mold (1), including a web body forming area (11) and bonding corner forming areas (12) located on both sides thereon; and according to the web structure design parameters, prefabricated bonding corner components are prepared in advance so that the geometry of the prefabricated bonding corner components matches the corresponding bonding corner forming areas (12); S2: The prefabricated adhesive corner component is attached and positioned on the adhesive corner forming area (12) on both sides of the web body forming area (11) by the positioning structure (14), and the fit between the prefabricated adhesive corner component and the adhesive corner forming area (12) is less than or equal to 1 mm. S3: Using the prefabricated adhesive corner member after positioning as the boundary reference, lay the main web layer (6) on the main web forming area (11) so that the edge of the main web layer (6) overlaps with the side wall of the prefabricated adhesive corner member to form a continuous connection and seamless fit. The joint is manually compacted. S4: After the layup is completed, a flow-guiding injection assembly (7) is laid on the web main body layup (6) according to the vacuum injection process requirements, and a vacuum film (8) is applied to the outside of the web forming mold (1) to perform overall vacuum sealing on the prefabricated adhesive corner member and the web main body layup (6) in the web forming mold (1). Resin is injected into the web forming mold (1) using the flow-guiding injection assembly (7) under vacuum or negative pressure environment, so that the resin penetrates the interface area of the web main body layup (6) and the prefabricated adhesive corner member, thereby realizing the integrated impregnation connection of the web main body layup (6) and the prefabricated adhesive corner member. S5: The resin is cured under vacuum or negative pressure conditions so that the prefabricated adhesive corner member and the web body layup (6) are cured to form an integral composite material structure; S6: After curing, demold the molded web and perform surface finishing and quality inspection.
2. The method for integral casting and molding of wind turbine blades according to claim 1, characterized in that, In step S2, before positioning the prefabricated adhesive corner component in the adhesive corner forming area (12), the web forming mold (1) is cleaned and its surface is polished to remove impurities and residual adhesive, and a release agent is applied to its surface; at the same time, the surface of each prefabricated adhesive corner component is cleaned to remove the release agent on its surface, improve its wetting state with the web body layup (6) during the injection molding process, and thus improve the interface bonding strength.
3. The method for integral casting and molding of wind turbine blades according to claim 1, characterized in that, In step S3, the outer structural layer (61), the core material layer (62) and the inner structural layer (63) are laid in the web body forming area (11) in a preset layup order to form the web body layup (6) with a symmetrical structure.
4. The method for integral casting and molding of wind turbine blades according to claim 1, characterized in that, The prefabricated adhesive corner component includes a T-shaped prefabricated block (2) and an L-shaped prefabricated block (3). The T-shaped prefabricated block (2) is disposed on one side of the main body forming area (11) of the web plate to form an adhesive corner structure on the leeward side of the web plate. The L-shaped prefabricated block (3) is disposed on the other side of the main body forming area (11) of the web plate to form an adhesive corner structure on the windward side of the web plate.
5. The method for integral casting and molding of wind turbine blades according to claim 4, characterized in that, The positioning structure (14) includes a pad block. The web forming mold (1) has a positioning groove (13) along its length on its leeward side. The pad block and the T-shaped precast block (2) are embedded in the positioning groove (13). The geometry of the pad block matches the side of the T-shaped precast block (2) away from the web main ply (6) to limit and support the T-shaped precast block (2).
6. The method for integral casting and molding of wind turbine blades according to claim 4, characterized in that, Both the T-shaped precast block (2) and the L-shaped precast block (3) have an R-angle (4) on the side facing the main web layer (6).
7. The method for integral casting and molding of wind turbine blades according to claim 4, characterized in that, The prefabricated adhesive corner component includes multiple T-shaped prefabricated blocks (2) and multiple L-shaped prefabricated blocks (3). The multiple T-shaped prefabricated blocks (2) and multiple L-shaped prefabricated blocks (3) are arranged continuously along the length direction of the web forming mold (1), and the splicing joint between adjacent T-shaped prefabricated blocks (2) or adjacent L-shaped prefabricated blocks (3) is less than 1 mm.
8. The method for integral casting and molding of wind turbine blades according to claim 7, characterized in that, The adjacent T-shaped precast blocks (2) and the adjacent L-shaped precast blocks (3) are connected by connectors (10). The connectors (10) are C-shaped fiber reinforced members. The two ends of the connectors (10) are respectively connected across the adjacent T-shaped precast blocks (2) or the adjacent L-shaped precast blocks (3).
9. The method for integral casting and molding of wind turbine blades according to claim 4, characterized in that, The side plates of the T-shaped precast block (2) and the L-shaped precast block (3) that overlap with the main web layer (6) are all provided with inclined transition structures (5).
10. The method for integral casting and molding of wind turbine blades according to claim 1, characterized in that, The flow guiding and injection assembly (7) includes a flow guiding net (71) and a flow channel (72). The flow guiding net (71) covers the web body ply (6) above it. The flow channel (72) is arranged above the flow guiding net (71) along the length direction of the web forming mold (1) and is located at the center position of the width direction of the web forming mold (1).