Foam contour plate

Abstract

The utility model discloses a foam contour plate which comprises a foam base material, a deep groove is machined in the first surface of the foam base material, and a shallow groove is machined in the second surface opposite to the first surface. The sum of the depths of the deep grooves and the shallow grooves is greater than or equal to the thickness of the foam base material; the deep grooves comprise transverse deep grooves and longitudinal deep grooves which are distributed all over the first surface of the foam base material, and the cross sections of the transverse deep grooves and the longitudinal deep grooves are V-shaped. According to the utility model, the deep groove is innovatively designed to be V-shaped, and a reasonable V-shaped gradient ratio is designed, so that the foam base material can reach an expected radian due to large deformation quantity of the V-shaped deep groove when splicing and laying are carried out at a specific position with a relatively large bending radian of the mold, further, the foam base material is effectively attached to the mold, and the conditions of local expansion, bulge and upwarp are avoided. In addition, the V-shaped deep groove at the bending position can be perfectly closed, so that the resin absorption can be reduced, the heat release peak can be reduced, and the risk of surface through printing can be reduced. The utility model is suitable for being used during the production of the wind power blade, and is used for forming a sandwich structure of the wind power blade.

Description

Technical Field

[0001] The utility model relates to the production of wind turbine blade core materials, in particular to a foam contour plate used for wind turbine blade core materials. Background Art

[0002] Currently, foam profile panels used as core materials for wind turbine blades typically utilize slotting and perforation to improve the core's ability to follow the blade's curved mold and prevent separation between the core and the panel (after resin infusion). For example, Chinese utility model patent No. CN215920991U discloses a foam sandwich core material with excellent mechanical properties. Deep grooves in a "Pozigzag" pattern are machined on the first surface of the foam substrate, while shallow grooves in a "cross" pattern are machined on the second surface. When forming the wind turbine blade, the foam substrate is infused with resin through a vacuum infusion process.

[0003] However, the cross-sections of the deep and shallow grooves of the existing foam profile panels are all rectangular, and the bottoms of the grooves are right angles. This structure often has the following problems:

[0004] One issue is the inability to effectively fit the mold. When the foam profile sheet is spliced ​​and laid in the blade mold, the shallow groove faces the mold and the deep groove faces away from it. At specific locations where the mold has a large curvature, the bottom of the groove is a right-angled rectangular deep groove. The groove opening is closed, but there is an opening at the bottom, forming a "△" shape. The rectangular deep groove has limited shape variation, resulting in the foam profile sheet not being able to achieve the desired curvature. The shallow groove cannot effectively fit the mold, and forced pressure will cause damage to the rectangular deep groove opening.

[0005] The second issue is the high volume of resin injected into the slots. On the one hand, the rectangular structure of deep and shallow slots absorbs a large amount of resin. On the other hand, the "△" shape formed at the bend, where the deep slots are not fully closed, absorbs a certain amount of resin. Excessive resin absorption increases the overall weight of the wind turbine blade, hindering weight reduction efforts and increasing production costs. Utility Model Content

[0006] In order to solve the above deficiencies in the prior art, the present invention aims to provide a foam contour plate to optimize the resin infusion volume and improve the fit with the mold.

[0007] To achieve the above-mentioned purpose, the technical solution adopted by the present invention is as follows: a foam contour plate, including a foam substrate, a first surface of the foam substrate is processed with deep grooves, and a second surface opposite to the first surface is processed with shallow grooves; the sum of the depths of the deep grooves and the shallow grooves is greater than or equal to the thickness of the foam substrate; the deep grooves include transverse deep grooves and longitudinal deep grooves throughout the first surface of the foam substrate, and the cross-sections of the transverse deep grooves and the longitudinal deep grooves are both V-shaped.

[0008] As a limitation of the present invention, the angle θ between the two V-shaped sides of the deep groove is 6±0.5°.

[0009] As a further limitation of the present invention, the groove spacing of the deep groove is 30±2 mm, and a connection of 2±0.5 mm is left at the bottom.

[0010] As another limitation of the present invention, the shallow grooves include transverse shallow grooves and longitudinal shallow grooves that are distributed throughout the second surface of the foam substrate, and the bottoms of the transverse shallow grooves and the longitudinal shallow grooves are both arc-shaped.

[0011] As a further limitation of the present invention, the cross-sections of the transverse shallow groove and the longitudinal shallow groove are both semi-elliptical.

[0012] As a further limitation of the present invention, the groove spacing of the shallow groove is 30±2 mm, the groove depth is 2±0.5 mm, and the groove width is 2±0.5 mm.

[0013] As a further limitation of the present invention, the transverse deep grooves and the longitudinal deep grooves divide the first surface of the foam substrate into a plurality of "squares";

[0014] Through holes are processed at all intersections of the horizontal shallow grooves and the longitudinal shallow grooves. The through holes penetrate the foam substrate and are located at the center of the "square".

[0015] As a third limitation of the present invention, a glass fiber mesh is bonded to the second surface of the foam substrate.

[0016] As a further limitation of the present invention, a guide net is laid on the first surface of the foam substrate.

[0017] As a further limitation of the present invention, a release cloth is laid on the first surface of the foam substrate above the guide mesh.

[0018] Due to the adoption of the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0019] (1) The utility model innovatively designs the deep groove into a V-shape and designs a reasonable V-shaped slope ratio. When splicing and laying layers at a specific location with a large curvature of the mold, the large deformation of the V-shaped deep groove allows the foam substrate to achieve the desired curvature, thereby effectively fitting the mold and avoiding local expansion and bulging, which may cause warping. In addition, the V-shaped deep groove at the curved position can be perfectly closed, thereby reducing resin absorption, lowering the exothermic peak, and reducing the risk of surface print-through.

[0020] (2) The utility model innovatively designs the shallow groove into a semi-elliptical shape and adopts an arc-shaped groove bottom. Compared with the rectangular groove in the prior art, the utility model can fully utilize the arc structure to improve the rigidity of the foam while reducing the amount of resin infusion, so that the foam strength can be enhanced, thereby making the most efficient use of the material.

[0021] In summary, the V-shaped deep groove and semi-elliptical shallow groove designed in the present invention achieve a reduction in the amount of resin infusion, which is of great significance to the lightweight design of wind turbine blades and can also appropriately reduce manufacturing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention will be described in further detail below with reference to the accompanying drawings and specific embodiments.

[0023] Figure 1 This is a schematic structural diagram of an embodiment of the present utility model;

[0024] Figure 2 This is a front view of the structure relationship of the first surface of an embodiment of the utility model;

[0025] Figure 3 This is a front view of the structural relationship of the second surface of an embodiment of the utility model;

[0026] Figure 4 A side view of the structural relationship of an embodiment of the utility model;

[0027] In the figure: 1. Foam substrate; 2. Deep groove; 3. Shallow groove; 4. Through hole. DETAILED DESCRIPTION

[0028] The preferred embodiments of the present invention are described below in conjunction with the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and understand the present invention and are not intended to limit the present invention.

[0029] Example 1 Foam contour board

[0030] like Figures 1 to 4 As shown, along the thickness direction of the foam substrate 1, the foam substrate 1 includes corresponding first and second surfaces. The first surface is machined with deep grooves 2 in a cross-shaped configuration, while the second surface is machined with shallow grooves 3 in a cross-shaped configuration. In this embodiment, the deep grooves 2 have a V-shaped cross section, while the shallow grooves 3 have a semi-elliptical cross section that forms an arc-shaped bottom.

[0031] It should be noted in advance that the directional terms such as horizontal and vertical in this embodiment are based on the symbols in the accompanying drawings. They are only for the convenience of describing this embodiment and are not used to limit this embodiment.

[0032] The manufacturing process of this embodiment is as follows:

[0033] First, after the foam substrate 1 is processed into a predetermined size, a plurality of horizontal shallow grooves and vertical shallow grooves are sequentially opened on the second surface of the foam substrate 1 using a slotting machine, such as Figure 3 As shown, the transverse shallow grooves and the longitudinal shallow grooves are distributed throughout the second surface of the foam substrate 1 , and each intersection of the transverse shallow grooves and the longitudinal shallow grooves forms a cross structure.

[0034] In this embodiment, the processing dimensions of the horizontal shallow grooves and the vertical shallow grooves are the same, that is, the groove spacing between the multiple horizontal shallow grooves is 30±2mm, the groove depth is 2±0.5mm, and the groove width is 2±0.5mm. Figure 4 As shown, both the transverse shallow groove and the longitudinal shallow groove are groove structures with a semi-elliptical cross-section, and the groove bottom is formed in an arc shape.

[0035] Next, a plurality of transverse deep grooves and longitudinal deep grooves are sequentially formed on the first surface of the foam substrate 1 using a slotting machine, such as Figure 2 As shown, transverse deep grooves and longitudinal deep grooves are distributed throughout the first surface of the foam substrate 1, dividing the first surface of the foam substrate 1 into multiple "squares." The transverse deep grooves are staggered with the transverse shallow grooves, and the longitudinal deep grooves are staggered with the longitudinal shallow grooves. At each intersection, the transverse deep grooves and longitudinal deep grooves form a cross structure.

[0036] In this embodiment, the processing dimensions of the transverse deep grooves and the longitudinal deep grooves are the same, that is, the groove spacing between the multiple transverse deep grooves is 30±2mm, and the connection at the bottom is 2±0.5mm; the groove spacing between the multiple longitudinal deep grooves is 30±2mm, and the connection at the bottom is 2±0.5mm. Figure 4 As shown, both the transverse deep grooves and the longitudinal deep grooves are V-shaped notch structures in cross section. The included angle θ between the two V-shaped sides of each deep groove 2 is 6±0.5°, and the notch width increases or decreases in proportion to the thickness of the foam substrate 1 .

[0037] Because deep groove 2 leaves a 2±0.5mm connection at the bottom and shallow groove 3 is 2±0.5mm deep, the actual dimensions must be determined to ensure that the combined depth of deep groove 2 and shallow groove 3 is greater than or equal to the thickness of foam substrate 1. This ensures that a gap is formed between deep groove 2 and shallow groove 3, connecting the two sides of foam substrate 1. When resin is infused into foam substrate 1 through the vacuum infusion process, this gap allows the resin to flow along the surface of foam substrate 1 to both sides, thereby forming a good bond between the laminate and the core material.

[0038] Finally, a through hole 4 is processed on the foam substrate 1 to penetrate the foam substrate 1, such as Figure 3 As shown, the through holes 4 are distributed at all intersections of the transverse shallow grooves and the longitudinal shallow grooves, as shown in FIG. Figure 2 As shown, the through hole 4 penetrates the foam substrate 1 from the second surface and is located at the center of the "square" on the first surface.

[0039] The through holes 4 have the same function as the above-mentioned slits, and are used to ensure that the resin can flow from the first surface to the second surface (i.e., from the bag surface of the foam substrate 1 to the mold surface) when the foam substrate 1 is infused with resin through the vacuum infusion process.

[0040] In order to prevent the block from falling off when the deep groove 2 is opened, in this embodiment, a glass fiber mesh cloth is bonded to the second surface of the foam substrate 1 where the shallow groove 3 is opened.

[0041] In this embodiment, a guide net is laid on the first surface of the foam substrate 1 with the deep grooves 2 to disperse the resin on the first surface; a release cloth is laid on the guide net to form a smooth surface.

[0042] It should be noted that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art may still modify the technical solutions described in the above embodiments or replace some of the technical features therein with equivalents. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A foam profile plate comprising a foam substrate, wherein a first surface of the foam substrate is processed with deep grooves, and a second surface opposite to the first surface is processed with shallow grooves; characterized in that: The sum of the depths of the deep grooves and the shallow grooves is greater than or equal to the thickness of the foam substrate; the deep grooves include transverse deep grooves and longitudinal deep grooves that are spread over the first surface of the foam substrate, and the cross sections of the transverse deep grooves and the longitudinal deep grooves are both V-shaped.

2. The foam contour board according to claim 1, characterized in that: The angle between the two V-shaped sides of the deep groove is θ=6±0.5°.

3. The foam contour board according to claim 2, characterized in that: The groove spacing of the deep groove is 30±2mm, and a connection of 2±0.5mm is left at the bottom.

4. A foam contour plate according to any one of claims 1 to 3, characterized in that: The shallow grooves include transverse shallow grooves and longitudinal shallow grooves which are distributed all over the second surface of the foam substrate. The bottoms of the transverse shallow grooves and the longitudinal shallow grooves are both arc-shaped.

5. The foam contour board according to claim 4, characterized in that: The cross sections of the transverse shallow groove and the longitudinal shallow groove are both semi-elliptical.

6. The foam contour board according to claim 5, characterized in that: The groove spacing of the shallow groove is 30±2mm, the groove depth is 2±0.5mm, and the groove width is 2±0.5mm.

7. The foam contour board according to claim 6, characterized in that: The transverse deep grooves and the longitudinal deep grooves divide the first surface of the foam substrate into a plurality of "squares"; Through holes are machined at all intersections of the horizontal shallow grooves and the longitudinal shallow grooves. The through holes penetrate the foam substrate and are located at the center of the "square".

8. A foam contour board according to any one of claims 1-3, 5-7, characterized in that: The second surface of the foam substrate is bonded with a glass fiber mesh cloth.

9. The foam contour board according to claim 8, characterized in that: The first surface of the foam substrate is paved with a flow guide net.

10. The foam contour board according to claim 9, characterized in that: A release cloth is laid on the first surface of the foam substrate above the guide mesh.

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