Reinforcing structure layer and wind power generation blade

Abstract

The application discloses a reinforced structure layer and a wind power generation blade. The reinforced structure layer comprises a plurality of fibers, the plurality of fibers comprising first fibers, second fibers and third fibers, any two of the first fibers, the second fibers and the third fibers being arranged at an angle, and the angles of any two being different, and the plurality of fibers being connected to form a structure layer, so that the extension directions of the plurality of fibers are towards multiple directions. Since any two of the first fibers, the second fibers and the third fibers are arranged at an angle, and the angles of any two are different, the extension directions of the plurality of fibers are towards multiple directions, an amorphous reinforcing form is formed, crack propagation in each direction can be effectively resisted, random crack propagation can be effectively coped with, and the reinforcing effect is more comprehensive.

Description

Technical Field

[0001] This application relates to the field of wind power generation technology, and in particular to a reinforced structural layer and a wind turbine blade. Background Technology

[0002] In the field of wind power generation, blades are one of the core components of wind turbine generators, and their performance directly affects the efficiency and reliability of the entire power generation system. Critical components such as the blade root interface and main sparsity interface bear enormous loads during operation, therefore, these interfaces need to be reinforced to reduce failures and improve the overall performance and lifespan of the blades.

[0003] In existing technologies, the main beam interface is typically reinforced using interlayer fabrics. The blade root interface is usually reinforced by wrapping continuous fibers around a UD block or bolt sleeve assembly to enhance its performance. However, existing reinforcement methods are highly orientation-dependent, only enhancing interface properties in a specific direction and failing to address the random propagation of cracks, resulting in poor reinforcement effectiveness. Summary of the Invention

[0004] The purpose of this application is to provide a reinforced structural layer and wind turbine blade that can effectively resist crack propagation in all directions, effectively cope with the random propagation of cracks, and provide a more comprehensive reinforcement effect.

[0005] In a first aspect, the present invention provides an enhanced structural layer, comprising:

[0006] A plurality of fibers, including a first fiber, a second fiber and a third fiber, wherein any two of the first fiber, the second fiber and the third fiber are arranged at an angle, and the angles between any two are different. The plurality of fibers are connected to form a structural layer, such that the extension directions of the plurality of fibers are oriented in multiple directions.

[0007] Beneficial effects: This reinforcing structure layer, where any two of the first, second, and third fibers are arranged at an angle, and these angles are not identical, allows the fibers to extend in multiple directions, forming an amorphous reinforcement. This effectively resists crack propagation in various directions, thus effectively addressing random crack propagation and providing a more comprehensive reinforcement effect. Compared to existing technologies that only enhance interface performance in one direction, this reinforcing structure layer provides reinforcement in multiple directions, reducing the risk of interface failure.

[0008] Furthermore, because the reinforcing structural layer is an amorphous reinforcement form, it is suitable not only for narrow and thin structural interfaces but also for blade root interfaces with large curvature and thickness. This allows the reinforcing structural layer to be widely used in various key interfaces of wind turbine blades, such as the blade root interface and the main beam interface. Compared to existing reinforcement schemes that are only applicable to specific shapes and thicknesses, this reinforcing structural layer has greater adaptability and can reinforce more types of components.

[0009] Taking wind turbine blades as an example, by incorporating a reinforcing structural layer into the blades and strengthening key components such as the blade root interface, the overall performance and lifespan of the wind turbine blades can be effectively improved. The reinforced blades can better withstand wind loads, reducing performance degradation caused by interface failure, thereby increasing the power generation efficiency of the wind turbine generator set. This also reduces blade damage and downtime caused by interface failure, thus improving the operating efficiency and reliability of the wind turbine generator set.

[0010] In one alternative embodiment, the length of each fiber is 1mm-150mm.

[0011] Beneficial effects: Since the fiber length in the reinforcing structural layer is 1mm-150mm, the fiber length is relatively short. When several short fibers are arranged and distributed, the extension direction of several fibers is easily oriented in multiple directions, forming an amorphous reinforcement form. This can effectively resist crack propagation in various directions, thereby effectively dealing with the random propagation of cracks, and the reinforcement effect is more comprehensive.

[0012] In one alternative embodiment, a plurality of the fibers are formed into the structural layer by a weaving or bonding process.

[0013] Beneficial effects: The weaving process allows fibers to intertwine and entwine, forming a tight and stable structural layer. This effectively restricts fiber displacement, enhances the synergistic effect between fibers, and thus improves the overall tensile and shear resistance of the structural layer. This allows it to maintain structural integrity under complex external forces, preventing deformation or disintegration. For example, in the dynamic working environment of wind turbine blades, it can better cope with various stress changes caused by wind loads.

[0014] The bonding process uses adhesives to firmly connect the fibers together, forming a continuous bonding interface between the fibers, which further enhances the integrity and stability of the structure and ensures that the performance of the structural layer will not decrease due to fiber loosening during long-term use.

[0015] Weaving or bonding helps achieve a uniform distribution of fibers in the structural layers, allowing stress to be transferred and dispersed more evenly across the fibers. When subjected to external forces, multiple fibers can share the load, preventing premature failure caused by localized stress concentration, thereby enhancing the reinforcement effect on the interface.

[0016] Weaving or bonding processes are relatively simple, making it easy to achieve large-scale production and reduce manufacturing costs.

[0017] In one optional embodiment, the reinforcing structural layer further includes a flexible support layer, the outer wall of which is covered with the structural layer, and the flexible support layer and the structural layer are formed into the reinforcing structural layer by a weaving process.

[0018] Beneficial effects: During the weaving process, several fibers are randomly arranged on a flexible support layer. The flexible support layer plays a stable foundation role, providing a relatively flat and stable bearing surface for the fibers. This allows the fibers to maintain the accuracy of their relative positions during arrangement and weaving, avoiding confusion and misalignment caused by the flexibility and fluidity of the fibers themselves. This not only helps to improve the efficiency of weaving, but also ensures that the final structural layer has a more uniform fiber distribution.

[0019] By combining the flexible support layer and the structural layer through a weaving process, a tightly connected whole is formed, which can effectively prevent relative sliding or separation between the structural layer and the flexible support layer, and ensure the integrity of the structural layer under long-term use and various working conditions.

[0020] In addition, the flexible support layer provides extra support and cushioning for the reinforced structural layer. When subjected to external forces, the flexible support layer can disperse stress, preventing stress concentration in localized areas of the structural layer and reducing the risk of fiber breakage. Compared to relying solely on the structural layer, the overall strength and toughness of the reinforced structural layer are significantly improved, enabling it to better maintain shape and performance stability under complex stress environments, such as the bending and torsion of wind turbine blades under strong winds, effectively enhancing the reliability and durability of the reinforced structural layer.

[0021] In one alternative embodiment, the reinforcing structural layer further includes an adhesive, the adhesive comprising 1%-12% of the total content of the reinforcing structural layer.

[0022] Beneficial effects: When the adhesive content accounts for 1%-12% of the total content of the reinforcing structural layer, the adhesive can provide sufficient bonding strength without causing the reinforcing structural layer to harden excessively and lose its flexibility. This allows the reinforcing structural layer to maintain a certain rigidity to withstand large loads while having a certain degree of flexibility to adapt to deformation, thus meeting the comprehensive requirements of structural performance for wind turbine blades under different working conditions.

[0023] Adhesives can fill the tiny gaps between fibers, allowing stress to be transferred more evenly and smoothly between fibers. This helps avoid stress concentration points, reduces the risk of structural damage caused by excessive local stress, further improves the reliability and durability of the reinforced structural layer, and extends its service life.

[0024] In one optional embodiment, the weight per unit area of ​​the structural layer is 'a', satisfying a ≤ 600 g / m². 2 .

[0025] Beneficial effects: By controlling the weight per unit area of ​​the structural layer to 600g / m² 2 The thinner and lighter structural layers contribute to a lighter overall design, which is beneficial in applications such as wind turbine blades. The reduced inertial forces required to overcome during blade rotation allow for a more rapid response to wind speed changes, improving the efficiency of converting wind energy into electricity.

[0026] In one alternative embodiment, the diameter of the fiber is d, which satisfies 9μm≤d≤24μm.

[0027] Beneficial effects: When the fiber diameter d satisfies 9μm≤d≤24μm, the fiber can achieve a good balance between strength and flexibility. Finer fibers (closer to 9μm) have a higher specific surface area, forming a tighter interfacial bond when combined with adhesives, which is beneficial for stress transfer and thus improves the overall strength of the reinforced structural layer. Relatively coarser fibers (closer to 24μm) provide better tensile and flexural strength, are less prone to breakage under greater external forces, and enhance the stability of the reinforced structural layer, making it more reliable under complex stress environments.

[0028] In one alternative embodiment, the fiber is at least one of glass fiber, carbon fiber, natural fiber, or thermoplastic fiber.

[0029] Beneficial effects: Glass fiber has high strength and good chemical stability, and is relatively low in cost. It can provide basic mechanical support and environmental resistance for reinforcing structural layers.

[0030] Carbon fiber has ultra-high strength and is lightweight, which can significantly improve the load-bearing capacity and rigidity of structures, meeting the application scenarios with high performance requirements.

[0031] Natural fibers such as hemp fiber and bamboo fiber have advantages such as being renewable, environmentally friendly, and having low density.

[0032] Thermoplastic fibers have good plasticity and processing properties, making it easy to form complex structural layers, which can improve production efficiency and product design flexibility.

[0033] By selecting at least one fiber material or combining multiple fibers, performance can be optimized and complemented according to specific application needs and cost budgets, thus meeting diverse engineering requirements.

[0034] Secondly, the present invention also provides a wind turbine blade, comprising:

[0035] A ply structure includes an inner ply and an outer ply spaced apart, wherein an accommodating cavity is formed between the inner ply and the outer ply;

[0036] A reinforcing structural layer is disposed within the accommodating cavity.

[0037] Beneficial Effects: This wind turbine blade incorporates a reinforcing structural layer within the space between the inner and outer ply layers. Because this reinforcing layer is amorphous, it effectively resists crack propagation in all directions, addressing random crack expansion. This significantly improves the overall performance and lifespan of the wind turbine blade. The reinforced blade can better withstand wind loads, reducing performance degradation caused by interface failure, thereby increasing the power generation efficiency of the wind turbine. It also reduces blade damage and downtime due to interface failure, thus improving the operational efficiency and reliability of the wind turbine.

[0038] Furthermore, since the reinforcing structural layer is an amorphous reinforcement form, it is suitable for blade root interfaces with large curved surfaces and large thicknesses, enabling the reinforcing structural layer to be widely used in various key interfaces of wind turbine blades, such as blade root interfaces and main beam interfaces.

[0039] In one optional embodiment, the wind turbine blade further includes a plurality of UD blocks, which are spaced apart within the receiving cavity, and the reinforcing structural layer is provided between the UD blocks and the inner ply and / or the outer ply.

[0040] Beneficial Effects: The UD block is a crucial load-bearing component in wind turbine blades and belongs to a high-risk area in terms of stress. Adding a reinforcing structural layer between the UD block and the inner and / or outer ply layers significantly enhances the connection strength between them. When wind turbine blades are subjected to wind forces, the forces between the UD block and the ply structure are enormous. The reinforcing structural layer can effectively disperse and transfer these stresses, preventing delamination and cracking due to weak connections, improving the overall reliability and stability of the blade structure, and ensuring safe and stable operation of the blade even under severe wind conditions.

[0041] In one optional embodiment, the inner ply includes a first connecting segment, a second connecting segment, and a third connecting segment connected in sequence, wherein the distance from the first connecting segment to the outer ply is greater than the distance from the third connecting segment to the outer ply.

[0042] Along the direction from the first connecting segment to the third connecting segment, the distance between the second connecting segment and the outer ply gradually decreases, the UD block extends from the first connecting segment to the second connecting segment, and the reinforcing structure layer extends from the first connecting segment to the third connecting segment.

[0043] Beneficial effects: The varying spacing between the inner ply and the outer ply creates a gradual structural transition. Along the direction from the first to the third connecting segment, the spacing between the second connecting segment and the outer ply gradually decreases, allowing for a smoother stress transfer from the inner to the outer ply. The extended UD block and reinforcing structural layers, in conjunction with this structure, further guide stress along a rational path, preventing stress concentration in localized areas. This effectively improves the overall stress-bearing capacity and structural stability of the blade, reducing the risk of blade damage due to stress concentration.

[0044] In one alternative embodiment, the reinforcing structural layer covers the outer wall surface of the UD block, and the UD block is located at the root of the wind turbine blade.

[0045] Beneficial effects: The root of a wind turbine blade is a critical part connecting the blade to the hub, bearing enormous loads and stresses. Placing the UD block at the root of the wind turbine blade and covering its outer wall with a reinforcing structural layer can greatly enhance the structural strength and connection stability of the root, ensuring a firm and reliable connection between the blade and the hub, and preventing serious problems such as loosening or detachment during operation.

[0046] In one optional embodiment, the wind turbine blade further includes a plurality of bolt sleeve assemblies, which are spaced apart within the receiving cavity. One bolt sleeve assembly is provided between any two adjacent UD blocks. The reinforcing structural layer covers the outer wall surface of the bolt sleeve assembly, and the bolt sleeve assembly is located at the root of the wind turbine blade.

[0047] Beneficial effects: Bolt sleeve assemblies are crucial structures connecting wind turbine blades to the hub and other components. Located at the root of the wind turbine blade, they provide a reliable mechanical connection point. Multiple bolt sleeve assemblies spaced apart allow for a more even distribution of connection force at the blade root, preventing excessive stress at any single point, enhancing the overall stability of the blade-hub connection, and preventing the risk of blade loosening or even detachment. Attached Figure Description

[0048] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0049] Figure 1 This is a schematic diagram of the internal fiber distribution of the reinforcing structural layer in one embodiment provided in this application;

[0050] Figure 2 This is a schematic diagram of a layered structure of the reinforcing structural layer in one embodiment provided in this application;

[0051] Figure 3 This is a schematic diagram of another layered structure for reinforcing the structural layer in one embodiment provided in this application;

[0052] Figure 4 This is a cross-sectional view of a wind turbine blade along its axial direction in one embodiment provided in this application;

[0053] Figure 5 This is a circumferential cross-sectional view of a wind turbine blade in one embodiment provided in this application:

[0054] Explanation of reference numerals in the attached figures:

[0055] 100. Reinforcing structural layer; 110. Fiber; 120. Structural layer; 130. Flexible support layer;

[0056] 200 Wind turbine blade; 210 Layered structure; 211 Inner layer; 2111 First connecting section; 2112 Second connecting section; 2113 Third connecting section; 212 Outer layer; 213 Accommodating cavity; 220 UD block; 230 Root; 240 Bolt sleeve assembly. Detailed Implementation

[0057] In the field of wind power generation, blades are one of the core components of wind turbine generators, and their performance directly affects the efficiency and reliability of the entire power generation system. Key components such as the blade root interface and main beam interface bear enormous loads during operation, thus requiring reinforcement of these interfaces to reduce failures and improve the overall performance and lifespan of the blades.

[0058] Currently, common interface enhancement solutions on the market are mainly divided into two categories: one is the enhancement method for the main beam interface, and the other is the enhancement method for the leaf root interface.

[0059] Interlaminar fabrics are commonly used to reinforce the interface of the main beam. These fabrics serve both to conduct current and enhance fracture toughness, effectively improving the interlaminar interface performance of the main beam. However, this reinforcement method is only suitable for thin and narrow interlaminar interfaces in the main beam and cannot be applied to interfaces with large curvature and thickness, such as those at the blade root. Furthermore, the reinforcing effect of interlaminar fabrics relies heavily on the continuity and orientation of the fibers. Interlaminar fabrics can reinforce both planar and perpendicular directions, resulting in a highly oriented reinforcement effect that often only enhances the interface performance in a single direction, failing to address the random propagation of cracks.

[0060] Strengthening methods for the blade root interface typically involve wrapping continuous fibers around a UD block or bolted sleeve assembly to enhance interface properties. However, this reinforcement method also exhibits high orientational characteristics, only improving interface properties in a specific direction. Due to the large curvature and thickness of the blade root interface, crack initiation and propagation are often randomly oriented. Existing reinforcement schemes cannot effectively enhance the interface properties in weak directions, resulting in poor reinforcement effects and increasing the risk of blade root failure.

[0061] To this end, this application attempted to design a reinforcing structural layer that could effectively resist crack propagation in all directions.

[0062] Based on this, since any two of the first, second, and third fibers are arranged at an angle, and the angles between any two are different, the extension directions of several fibers can be directed in multiple directions, forming an amorphous reinforcement form. This can effectively resist crack propagation in various directions, thereby effectively dealing with the random propagation of cracks and providing a more comprehensive reinforcement effect.

[0063] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of this application, but not all embodiments.

[0064] To solve the above technical problems, the following will be combined with... Figures 1 to 5 The following describes embodiments of the present invention.

[0065] According to an embodiment of the present invention, in one aspect, such as Figures 1 to 3 As shown, a reinforced structural layer is provided, comprising a plurality of fibers 110.

[0066] Specifically, such as Figure 1As shown, a plurality of fibers 110 include a first fiber, a second fiber, and a third fiber, wherein any two of the first, second, and third fibers are arranged at an angle, and the angles between any two fibers are not the same. The plurality of fibers 110 are connected to form a structural layer 120, such that the extension directions of the plurality of fibers 110 are oriented in multiple directions.

[0067] This reinforcing structure layer, because any two of the first, second, and third fibers are arranged at an angle, and the angles between any two are different, allows the extension directions of the fibers 110 to face multiple directions, forming an amorphous reinforcement. This effectively resists crack propagation in various directions, thus effectively addressing the random propagation of cracks, resulting in a more comprehensive reinforcement effect. Compared to existing technologies that can only enhance interface performance in one direction, this reinforcing structure layer 100 can provide reinforcement in multiple directions, reducing the risk of interface failure.

[0068] Furthermore, since the reinforcing structural layer 100 is an amorphous reinforcement, it is suitable not only for narrow and thin structural interfaces but also for blade root interfaces with large curvature and thickness. This allows the reinforcing structural layer 100 to be widely used in various key interfaces of wind turbine blades 200, such as the blade root interface and the main beam interface. Compared to existing reinforcement schemes that are only applicable to specific shapes and thicknesses, the reinforcing structural layer 100 has greater adaptability and can reinforce more types of components.

[0069] Taking a wind turbine blade 200 as an example, the reinforcing structural layer 100 is installed on the wind turbine blade 200. By reinforcing key components such as the blade root interface, the overall performance and lifespan of the wind turbine blade 200 can be effectively improved. The reinforced wind turbine blade 200 can better withstand wind loads, reducing performance degradation caused by interface failure, thereby improving the power generation efficiency of the wind turbine generator set. This also reduces blade damage and downtime caused by interface failure, thus improving the operating efficiency and reliability of the wind turbine generator set.

[0070] Specifically, fiber 110 may further include a fourth fiber, a fifth fiber, etc., wherein the fourth fiber and the fifth fiber may be arranged at an angle or not. The angle between the fourth fiber and the fifth fiber may be the same as or different from the angle between the first fiber and the second fiber.

[0071] It should be noted that if fiber 110 is curved or arc-shaped, the direction of extension of the curve or arc at each point is the tangent direction at that point.

[0072] Specifically, the fiber 110 can be any existing fiber material such as glass fiber, hemp fiber, bamboo fiber, or carbon fiber. In this embodiment, no specific restrictions are placed on the material of the fiber 110.

[0073] In one embodiment, the length of each fiber 110 is 1mm-150mm.

[0074] Since the fiber 110 in the reinforcing structural layer 100 has a length of 1mm-150mm, the fiber 110 is relatively short. When several short fibers 110 are arranged and distributed, the extension direction of several fibers 110 is easily oriented in multiple directions, forming an amorphous reinforcement form. This can effectively resist crack propagation in various directions, thereby effectively dealing with the random propagation of cracks, and the reinforcement effect is more comprehensive.

[0075] Specifically, when the fiber 110 is too short (e.g., much shorter than 1 mm), its reinforcing effect is significantly weakened. The entanglement and interaction between fibers 110 decrease, making it difficult to form a stable and effective reinforcing network structure. Under external forces, the fibers 110 are prone to pull-out or the overall structure becomes loose, failing to fully exert its reinforcing effect on the interface, thus reducing the mechanical properties and reliability of the reinforcing layer 100.

[0076] Specifically, when the fiber 110 is too long (e.g., much longer than 150 mm), the excessively long fiber 110 is prone to forming a certain orientation when randomly arranged, resulting in a directional reinforcement effect, which contradicts the original design intention of amorphous reinforcement and makes it impossible to achieve comprehensive reinforcement in multiple directions.

[0077] Specifically, the length of the fiber 110 is set in the range of 1mm-150mm. When several fibers 110 are randomly arranged, the extension direction of the fibers 110 can be oriented in multiple directions, forming good connectivity and ensuring the integrity and consistency of the reinforcing structure layer 100.

[0078] In one embodiment, a plurality of fibers 110 are formed into a structural layer 120 by a weaving or bonding process.

[0079] The weaving process allows the fibers 110 to interweave and entwine, forming a tight and stable structural layer 120. This effectively restricts the displacement of the fibers 110 and enhances the synergistic effect between them, thereby improving the tensile and shear resistance of the overall structural layer 120. This allows it to maintain structural integrity under complex external forces and is less prone to deformation or disintegration. For example, in the dynamic working environment of a wind turbine blade 200, it can better cope with various stress changes caused by wind loads.

[0080] The bonding process uses an adhesive to firmly connect the fibers 110 together, forming a continuous bonding interface between the fibers 110, which further enhances the integrity and stability of the structure and ensures that the performance of the structural layer 120 will not be reduced due to the loosening of the fibers 110 during long-term use.

[0081] Weaving or bonding helps to achieve a uniform distribution of fibers 110 in the structural layer 120, allowing stress to be transferred and dispersed more evenly to each fiber 110. When subjected to external forces, multiple fibers 110 can share the load, avoiding premature failure caused by local stress concentration, thereby improving the reinforcement effect on the interface.

[0082] Weaving or bonding processes are relatively simple, making it easy to achieve large-scale production and reduce manufacturing costs.

[0083] Specifically, when weaving the fibers 110, several fibers 110 can be woven into a structural layer 120 using weaving techniques such as plain weave, twill weave, or satin weave. In this embodiment, no specific limitation is made on the weaving method.

[0084] It should be noted that when weaving fiber 110, an appropriate amount of adhesive can also be added to bond the fiber 110 together to ensure that the fiber 110 is firmly connected.

[0085] Specifically, when bonding fibers 110, several fibers 110 can be bonded into a structural layer 120 through bonding processes such as hot pressing, chemical adhesive bonding, and mechanically assisted bonding. In the embodiments of this application, no specific limitation is made on the bonding method.

[0086] For example, several fibers 110 are bonded together by a hot pressing device under certain temperature and pressure, so that the structural layer 120 has high bonding strength and good interface performance, which is suitable for the main beam interface, blade root interface, etc. of wind turbine blade 200.

[0087] In one embodiment, such as Figure 2 and Figure 3 As shown, the reinforcing structural layer 100 also includes a flexible support layer 130, wherein a structural layer 120 is covered on the outer wall surface of the flexible support layer 130, and the flexible support layer 130 and the structural layer 120 are formed into the reinforcing structural layer 100 by a weaving process.

[0088] During the weaving process, several fibers 110 are randomly arranged on the flexible support layer 130. The flexible support layer 130 plays a stable foundation role, providing a relatively flat and stable bearing surface for the fibers 110. This allows the fibers 110 to maintain the accuracy of their relative positions during arrangement and weaving, avoiding confusion and misalignment caused by the flexibility and fluidity of the fibers 110 themselves. This not only helps to improve the efficiency of weaving, but also ensures that the final structural layer 120 has a more uniform distribution of fibers 110.

[0089] The flexible support layer 130 and the structural layer 120 are combined by a weaving process to form a tightly connected whole, which can effectively prevent relative sliding or separation between the structural layer 120 and the flexible support layer 130, and ensure the integrity of the structural layer 100 under long-term use and various working conditions.

[0090] In addition, the flexible support layer 130 provides extra support and cushioning for the reinforcing structural layer 100. When subjected to external forces, the flexible support layer 130 can disperse stress, preventing stress concentration in localized areas of the structural layer 120 and reducing the risk of fiber 110 breakage. Compared to relying solely on the structural layer 120, the overall strength and toughness of the reinforcing structural layer 100 are significantly improved, enabling it to better maintain its shape and performance stability under complex stress environments, such as bending and torsion of the wind turbine blade 200 under strong winds, effectively enhancing the reliability and durability of the reinforcing structural layer 100.

[0091] Specifically, such as Figure 2 As shown, a structural layer 120 can be provided to cover one side of the flexible support layer 130. For example... Figure 3 As shown, two structural layers 120 can be provided, covering opposite sides of the flexible support layer 130 respectively, to further improve the reliability and durability of the reinforced structural layer 100. In this embodiment, the number of structural layers 120 is not specifically limited.

[0092] In one embodiment, the reinforcing structural layer 100 further includes an adhesive, the content of which is 1%-12% of the content of the reinforcing structural layer 100.

[0093] When the adhesive content accounts for 1%-12% of the total content of the reinforcing structural layer 100, the adhesive can provide sufficient bonding strength without causing the reinforcing structural layer 100 to over-harden and lose its flexibility. This allows the reinforcing structural layer 100 to maintain a certain rigidity to withstand large loads while having a certain degree of flexibility to adapt to deformation, thus meeting the comprehensive requirements of structural performance for wind turbine blades 200 under different working conditions.

[0094] The adhesive can fill the tiny gaps between the fibers 110, allowing stress to be transmitted more evenly and smoothly between the fibers 110. This helps to avoid the generation of stress concentration points, reduce the risk of structural damage caused by excessive local stress, further improve the reliability and durability of the reinforcing layer 100, and extend its service life.

[0095] Specifically, if the adhesive content is too high, it will cause the reinforcing structural layer 100 to over-harden. Excessive adhesive will fill a large amount of space, causing the reinforcing structural layer 100 to lose its proper flexibility. When subjected to external forces, it will be difficult to deform appropriately to distribute stress. Instead, it is prone to cracking or breaking due to stress concentration in areas with higher rigidity, thus reducing the overall reliability and durability of the reinforcing structural layer 100.

[0096] Specifically, if the adhesive content is too low, the bonding force between fibers 110 will be insufficient. When subjected to external force, fibers 110 are prone to relative sliding and displacement, and cannot work together effectively. This results in a significant decrease in the overall strength and stability of the reinforcing structural layer 100, and the expected reinforcement effect cannot be achieved.

[0097] Specifically, the adhesive can be an existing adhesive such as epoxy resin or polyurethane. In the embodiments of this application, no specific limitation is made on the type of adhesive.

[0098] For example, epoxy resin has excellent adhesive properties and can produce strong adhesion to a variety of fiber 110 materials. The reinforced structural layer 100 formed after curing has high strength and good chemical stability, and can maintain the adhesive effect under different environmental conditions, ensuring the long-term stability of the reinforced structural layer 100.

[0099] In one embodiment, the weight per unit area of ​​structural layer 120 is 'a', which satisfies a ≤ 600 g / m². 2 .

[0100] By controlling the weight of the structural layer 120 per unit area to 600g / m² 2 The thinner and lighter structural layer 120 makes it more suitable for applications such as wind turbine blades 200, which helps to achieve a lightweight design for the entire component. The reduced inertial force required to overcome during rotation allows the wind turbine blade 200 to respond more quickly to changes in wind speed, improving the efficiency of converting wind energy into electrical energy.

[0101] Specifically, if a > 600 g / m 2 In the application of wind turbine blade 200, the excessively heavy structural layer 120 will significantly increase the overall weight of wind turbine blade 200, causing the wind turbine to consume more energy to drive the blade rotation during operation, thus reducing the efficiency of converting wind energy into electrical energy.

[0102] In one embodiment, the diameter of fiber 110 is d, which satisfies 9μm≤d≤24μm.

[0103] When the diameter d of fiber 110 satisfies 9μm≤d≤24μm, fiber 110 can achieve a good balance between strength and flexibility. Finer fibers 110 (close to 9μm) have a higher specific surface area, forming a tighter interfacial bond when combined with adhesives, which is beneficial for stress transfer and thus improves the overall strength of the reinforcing layer 100. Relatively coarser fibers 110 (close to 24μm) provide better tensile and flexural strength, are less prone to breakage under greater external forces, and enhance the stability of the reinforcing layer 100, making it more reliable under complex stress environments.

[0104] Specifically, if the diameter of fiber 110 is too small, it is prone to entanglement during weaving or other forming processes, increasing the complexity and difficulty of processing operations and seriously affecting production efficiency. Furthermore, an excessively small diameter results in relatively low strength of fiber 110 itself, making it prone to breakage under external forces.

[0105] Specifically, if the diameter of the fiber 110 is too large, the reinforcing structural layer 100 becomes rigid and loses its flexibility. When faced with situations that require a certain deformation capacity to disperse stress, such as the dynamic bending and twisting of the wind turbine blade 200 in the wind, the reinforcing structural layer 100 is difficult to adapt and is prone to cracks or fractures due to stress concentration in rigid parts, thus reducing the structure's resistance to damage.

[0106] In one embodiment, fiber 110 is at least one of glass fiber, carbon fiber, natural fiber or thermoplastic fiber.

[0107] Glass fiber has high strength and good chemical stability, and is relatively inexpensive, providing basic mechanical support and environmental resistance for the reinforcing structural layer 100.

[0108] Carbon fiber has ultra-high strength and is lightweight, which can significantly improve the load-bearing capacity and rigidity of structures, meeting the application scenarios with high performance requirements.

[0109] Natural fibers such as hemp fiber and bamboo fiber have advantages such as being renewable, environmentally friendly, and having low density.

[0110] Thermoplastic fibers have good plasticity and processing properties, making it easy to form complex structural layers 120, which can improve production efficiency and product design flexibility.

[0111] By selecting at least one fiber 110 material, or combining multiple fibers 110, performance can be optimized and complemented according to specific application needs and cost budgets, thus meeting diverse engineering requirements.

[0112] For example, in scenarios requiring high performance, carbon fiber can be used as the primary material, supplemented by thermoplastic fibers to improve recyclability.

[0113] For example, in extreme environmental scenarios, a combination of carbon fiber and glass fiber can be used to enhance corrosion resistance and fatigue resistance.

[0114] According to an embodiment of the present invention, on the other hand, such as Figures 1 to 5 As shown, a wind turbine blade 200 is also provided, including a ply structure 210 and a reinforcing structure layer 100.

[0115] Specifically, such as Figure 4 As shown, the ply structure 210 includes an inner ply 211 and an outer ply 212, wherein the inner ply 211 and the outer ply 212 are spaced apart, and a cavity 213 is formed between the inner ply 211 and the outer ply 212.

[0116] Specifically, such as Figure 4 As shown, the reinforcing structure layer 100 is disposed within the accommodating cavity 213.

[0117] This wind turbine blade 200 incorporates a reinforcing structural layer 100 within the space between the inner ply 211 and the outer ply 212. Because the reinforcing structural layer 100 is an amorphous reinforcement, it effectively resists crack propagation in all directions and addresses the random propagation of cracks, thereby significantly improving the overall performance and lifespan of the wind turbine blade 200. The reinforced blade 200 can better withstand wind loads, reducing performance degradation caused by interface failure, thus improving the power generation efficiency of the wind turbine generator. It also reduces blade damage and downtime due to interface failure, thereby improving the operating efficiency and reliability of the wind turbine generator.

[0118] Furthermore, since the reinforcing structural layer 100 is an amorphous reinforcement form, it is suitable for blade root interfaces with large curved surfaces and large thicknesses, enabling the reinforcing structural layer 100 to be widely used in various key interfaces of wind turbine blades 200, such as blade root interfaces and main beam interfaces.

[0119] Specifically, the inner layer 211 and the outer layer 212 can be configured with any existing shape. For example, the outer layer 212 can be configured as a smooth plane or curved surface to reduce wind resistance. The inner layer 211 can be configured with a shape that matches the shape of the filler between the inner layer 211 and the outer layer 212. In this embodiment, the shapes of the inner layer 211 and the outer layer 212 are not specifically limited.

[0120] Specifically, a single reinforcing structure layer 100 or multiple reinforcing structure layers 100 may be provided inside the cavity 213. The specific arrangement can be adapted according to the actual use scenario of the wind turbine blade 200. In this embodiment, the number of reinforcing structure layers 100 inside the cavity 213 is not specifically limited.

[0121] Specifically, the reinforcing structural layer 100 may be provided only in a portion of the cavity 213 or in the entire cavity 213.

[0122] In one embodiment, such as Figure 4 As shown, the wind turbine blade 200 also includes a plurality of UD blocks 220, which are spaced apart in the receiving cavity 213. A reinforcing structural layer 100 is provided between the UD blocks 220 and the inner paving layer 211 and / or the outer paving layer 212.

[0123] The UD block 220 is a crucial load-bearing component of the wind turbine blade 200, belonging to a high-risk area in terms of stress. The reinforcing structural layer 100, placed between the UD block 220 and the inner ply 211 and / or outer ply 212, significantly enhances the connection strength between them. When the wind turbine blade 200 is subjected to wind force, the force between the UD block 220 and the ply structure 210 is substantial. The reinforcing structural layer 100 effectively disperses and transfers these stresses, preventing delamination and cracking due to weak connections. This improves the overall reliability and stability of the wind turbine blade 200, ensuring its safe and stable operation even under severe wind conditions.

[0124] It should be noted that UD Block 220 (UniDirectional Block) is a type of reinforcing structural layer 100 unit in composite materials, composed of unidirectional continuous fibers 110 (such as carbon fiber or glass fiber) and a resin matrix (such as epoxy resin). The core feature of UD Block 220 is that the fibers 110 are highly oriented along a single direction, forming extremely high axial strength and stiffness, and is often used in critical parts that bear high loads in a specific direction.

[0125] Specifically, the reinforcing structural layer 100 can be disposed between the UD block 220 and the inner paving layer 211, or between the UD block 220 and the outer paving layer 212, or both between the UD block 220 and the inner paving layer 211 and between the UD block 220 and the outer paving layer 212.

[0126] In one embodiment, such as Figure 4 As shown, the inner ply 211 includes a first connecting segment 2111, a second connecting segment 2112, and a third connecting segment 2113, which are connected sequentially. The distance between the first connecting segment 2111 and the outer ply 212 is greater than the distance between the third connecting segment 2113 and the outer ply 212.

[0127] Along the direction from the first connecting segment 2111 to the third connecting segment 2113, the spacing between the second connecting segment 2112 and the outer layer 212 gradually decreases, the UD block 220 extends from the first connecting segment 2111 to the second connecting segment 2112, and the reinforcing structural layer 100 extends from the first connecting segment 2111 to the third connecting segment 2113.

[0128] The varying spacing between different connecting sections of the inner ply 211 and the outer ply 212 creates a gradual structural change. Along the direction from the first connecting section 2111 to the third connecting section 2113, the spacing between the second connecting section 2112 and the outer ply 212 gradually decreases, allowing for a smoother stress transition from the inner ply 211 to the outer ply 212 during transmission. The extended arrangement of the UD block 220 and the reinforcing structural layer 100 complements this structure, further guiding stress along a reasonable path, avoiding stress concentration in localized areas, effectively improving the overall stress-bearing capacity and structural stability of the wind turbine blade 200, and reducing the risk of damage to the wind turbine blade 200 due to stress concentration.

[0129] In actual operation, the wind force and stress experienced by different parts of the wind turbine blade 200 are complex and diverse. The root region 230 near the blade 200 typically bears greater bending moment and shear force, while the tip experiences relatively less stress. The design structure of the inner liner 211 and the layout of the UD block 220 and the reinforcing structure layer 100 better adapt to the stress characteristics of the wind turbine blade 200. The changes from the first connecting section 2111 to the third connecting section 2113 and the corresponding component settings ensure that the wind turbine blade 200 receives appropriate reinforcement and support in different stress areas, improving its performance under various operating conditions and enhancing its adaptability to complex wind farm environments.

[0130] By rationally designing the extension range of the UD block 220 and the reinforcing structural layer 100, materials can be precisely configured according to the stress requirements of different parts of the wind turbine blade 200. In areas with higher stress, such as near the first connecting section 2111, the UD block 220 and the reinforcing structural layer 100 can provide stronger reinforcement; while in areas with lower stress, the amount of material used and the degree of reinforcement are correspondingly reduced. This improves material utilization and reduces production costs while ensuring the performance of the wind turbine blade 200, and also helps to reduce the weight of the wind turbine blade 200 and improve the energy conversion efficiency of the wind power generation system.

[0131] It should be noted that this application defines the direction along the first connecting segment 2111 to the third connecting segment 2113 as follows: Figure 4 The direction indicated by the middle arrow.

[0132] Specifically, the first connecting section 2111 and the third connecting section 2113 can be arranged parallel to the outer layer 212, and the second connecting section 2112 is arranged at an angle relative to the outer layer 212.

[0133] In one embodiment, such as Figure 4 As shown, the reinforcing structure layer 100 covers the outer wall of the UD block 220, and the UD block 220 is disposed at the root 230 of the wind turbine blade 200.

[0134] The root 230 of the wind turbine blade 200 is a critical part connecting the wind turbine blade 200 to the hub, bearing enormous loads and stresses. Placing the UD block 220 at the root 230 of the wind turbine blade 200 and covering its outer wall with the reinforcing structural layer 100 significantly enhances the structural strength and connection stability of the root 230, ensuring a firm and reliable connection between the wind turbine blade 200 and the hub, and preventing serious problems such as loosening or detachment during operation.

[0135] When wind force acts on the wind turbine blade 200, highly concentrated stress is generated at the root 230. The reinforcing structural layer 100 covering the UD block 220 can effectively disperse these concentrated stresses over a larger area. Through the synergistic effect of the reinforcing structural layer 100 and the UD block 220, the stress can be more evenly transmitted to other parts of the wind turbine blade 200, thereby reducing the situation of excessive local stress at the root 230, reducing the risk of fatigue cracks and damage at the root 230, and extending the service life of the wind turbine blade 200.

[0136] Specifically, the outer wall of the UD block 220 may be covered with one layer of reinforcing structure layer 100 or multiple layers of reinforcing structure layer 100. In this embodiment, the number of reinforcing structure layer 100 layers on the outer wall of the UD block 220 is not specifically limited.

[0137] In one embodiment, the wind turbine blade 200 further includes a plurality of bolt sleeve assemblies 240, which are spaced apart in the receiving cavity 213. A bolt sleeve assembly 240 is provided between any two adjacent UD blocks 220. The reinforcing structural layer 100 covers the outer wall of the bolt sleeve assembly 240, and the bolt sleeve assembly 240 is provided at the root 230 of the wind turbine blade 200.

[0138] The bolt sleeve assembly 240 is a crucial structure connecting the wind turbine blade 200 to other components such as the hub. Located at the root 230 of the wind turbine blade 200, it provides a reliable mechanical connection point. The spaced distribution of multiple bolt sleeve assemblies 240 allows for a more even distribution of connection force at the root 230 of the wind turbine blade 200, preventing excessive stress at any single point, enhancing the overall stability of the connection between the wind turbine blade 200 and the hub, and preventing the risk of the wind turbine blade 200 loosening or even detaching.

[0139] A bolt sleeve assembly 240 is installed between two adjacent UD blocks 220 to ensure that the bolt sleeve assembly 240 is securely installed at the root 230 of the wind turbine blade 200. The reinforcing structural layer 100 covers the outer wall of the bolt sleeve assembly 240, creating a good stress transfer path between the bolt sleeve assembly 240 and the wind turbine blade 200. When the wind turbine blade 200 is subjected to wind force, the load borne by the bolt sleeve assembly 240 can be more effectively transferred to other parts of the wind turbine blade 200 through the reinforcing structural layer 100. Working in conjunction with the UD blocks 220, it further disperses the stress at the root 230, reduces stress concentration, improves the fatigue resistance and load-bearing capacity of the root 230 of the wind turbine blade 200, and extends the service life of the wind turbine blade 200.

[0140] To better illustrate the reinforcing effect of the reinforced structural layer, the following experimental test is used as an example:

[0141] Example 1:

[0142] The reinforcing structural layer 100 is woven from fibers 110. The area weight of the fibers 110 is 200 g / m². 2 The material used for fiber 110 is carbon fiber. The length of fiber 110 is 5 mm and the diameter of fiber 110 is 10 μm. When this reinforcing structure layer 100 is laid between UD block 220 and ply structure 210, the type I fracture toughness of the interface can be increased by 80%.

[0143] Example 2:

[0144] The reinforcing structural layer 100 is made of bonded fibers 110. The weight per unit area of ​​the fibers 110 is 500 g / m². 2 The adhesive content of fiber 110 accounts for 2% of the content of the reinforcing structure layer. The material type used for fiber 110 is thermoplastic fiber. The length of fiber 110 is 10mm and the diameter of fiber 110 is 15μm. When this reinforcing structure layer 100 is laid between the inner layer 211 and the outer layer 212, the type I fracture toughness of the interface can be increased by 60%.

[0145] Example 3:

[0146] The reinforcing structural layer 100 is made of bonded fibers 110. The weight per unit area of ​​the fibers 110 is 350 g / m². 2 The adhesive content of fiber 110 accounts for 10% of the content of reinforcing structural layer 100. The material type used for fiber 110 is glass fiber. The length of fiber 110 is 20 mm and the diameter of fiber 110 is 18 μm. This reinforcing structural layer 100 is wrapped around bolt sleeve assembly 240, and bolt sleeve assembly 240 is located at the root of wind turbine blade 200, which can improve the type I fracture toughness at the interface by 120%.

[0147] Comparative Example 1:

[0148] The reinforcing structural layer 100 is woven from fibers 110. The weight per unit area of ​​the fibers 110 is 500 g / m². 2 The material used for fiber 110 is carbon fiber, the length of fiber 110 is 200mm, and the diameter of fiber 110 is 10μm. When this reinforcing structure layer 100 is laid between UD block 220 and ply structure 210, the type I fracture toughness at the interface can be increased by 20%.

[0149] Comparative Example 2:

[0150] The reinforcing structural layer 100 is made of bonded fibers 110. The weight per unit area of ​​the fibers 110 is 800 g / m². 2 The binder content of fiber 110 accounts for 2% of the content of reinforcing structural layer 100. The material type used for fiber 110 is thermoplastic fiber, the length of fiber 110 is 10 mm, and the diameter of fiber 110 is 15 μm. When this reinforcing structural layer 100 is laid between inner layer 211 and outer layer 212, the type I fracture toughness of the interface can be reduced by 10%.

[0151] Comparative Example 3:

[0152] The reinforcing structural layer 100 is made of bonded fibers 110. The weight per unit area of ​​the fibers 110 is 350 g / m². 2 The adhesive content of fiber 110 accounts for 20% of the content of reinforcing structural layer 100. The material type used for fiber 110 is glass fiber. The length of fiber 110 is 20 mm and the diameter of fiber 110 is 18 μm. The reinforcing structural layer 110 is wrapped around bolt sleeve assembly 240, and bolt sleeve assembly 240 is located at the root 230 of wind turbine blade 200, which can reduce the type I fracture toughness at the interface by 30%.

[0153] The terms "upper" and "lower" are used to describe the relative positions of the various structures in the accompanying drawings. They are only for clarity of description and are not intended to limit the scope of implementation of this application. Any changes or adjustments to the relative positions without substantially altering the technical content shall also be considered within the scope of implementation of this application.

[0154] It should be noted that, in this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0155] Furthermore, in this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0156] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this disclosure. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0157] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A reinforcing structural layer, characterized in that, include: A plurality of fibers (110), including a first fiber, a second fiber and a third fiber, wherein any two of the first fiber, the second fiber and the third fiber are arranged at an angle, and the angles formed by any two are different. The plurality of fibers (110) are connected to form a structural layer (120) so that the extension direction of the plurality of fibers (110) is oriented in multiple directions.

2. The reinforcing structural layer according to claim 1, characterized in that, Each fiber (110) has a length of 1mm-150mm.

3. The reinforcing structural layer according to claim 2, characterized in that, The structural layer (120) is formed by a plurality of the fibers (110) through a weaving or bonding process.

4. The reinforcing structural layer according to claim 3, characterized in that, The reinforcing structural layer (100) further includes a flexible support layer (130), the outer wall of which is covered with the structural layer (120), and the flexible support layer (130) and the structural layer (120) are formed by a weaving process to form the reinforcing structural layer (100).

5. The reinforcing structural layer according to claim 3, characterized in that, The reinforcing structural layer (100) further includes an adhesive, the content of which is 1%-12% of the content of the reinforcing structural layer (100).

6. The reinforcing structural layer according to claim 2, characterized in that, The weight per unit area of ​​the structural layer (120) is a, which satisfies a≤600g / m² 2 .

7. The reinforcing structural layer according to claim 2, characterized in that, The diameter of the fiber (110) is d, which satisfies 9μm≤d≤24μm.

8. The reinforcing structural layer according to any one of claims 1 to 7, characterized in that, The fiber (110) is at least one of glass fiber, carbon fiber, natural fiber or thermoplastic fiber.

9. A wind turbine blade, characterized in that, include: The ply structure (210) includes an inner ply (211) and an outer ply (212) spaced apart, wherein an accommodating cavity (213) is formed between the inner ply (211) and the outer ply (212); The reinforcing structural layer according to any one of claims 1 to 8, wherein the reinforcing structural layer (100) is disposed within the receiving cavity (213).

10. The wind turbine blade according to claim 9, characterized in that, The wind turbine blade (200) also includes a plurality of UD blocks (220), which are spaced apart in the accommodating cavity (213). The reinforcing structure layer (100) is provided between the UD blocks (220) and the inner paving layer (211) and / or the outer paving layer (212).

11. The wind turbine blade according to claim 10, characterized in that, The inner paving layer (211) includes a first connecting segment (2111), a second connecting segment (2112), and a third connecting segment (2113) connected in sequence. The distance between the first connecting segment (2111) and the outer paving layer (212) is greater than the distance between the third connecting segment (2113) and the outer paving layer (212). Along the direction from the first connecting segment (2111) to the third connecting segment (2113), the distance between the second connecting segment (2112) and the outer layer (212) gradually decreases, the UD block (220) extends from the first connecting segment (2111) to the second connecting segment (2112), and the reinforcing structure layer (100) extends from the first connecting segment (2111) to the third connecting segment (2113).

12. The wind turbine blade according to claim 10, characterized in that, The reinforcing structural layer (100) covers the outer wall of the UD block (220), and the UD block (220) is located at the root (230) of the wind turbine blade (200).

13. The wind turbine blade according to claim 10, characterized in that, The wind turbine blade (200) also includes a plurality of bolt sleeve assemblies (240), which are spaced apart in the accommodating cavity (213). A bolt sleeve assembly (240) is provided between any two adjacent UD blocks (220). The reinforcing structural layer (100) covers the outer wall of the bolt sleeve assembly (240), and the bolt sleeve assembly (240) is located at the root (230) of the wind turbine blade (200).

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