Orthogonal structural components, manufacturing techniques, and thin film materials in multifilamentary composites

Abstract

To provide a manufacturing method for an orthogonal structural member in a multi-chamber type fibrous composite material.SOLUTION: A disclosed method includes: a step of preparing a preformed core body by forming a foam material chamber for including a foam material by using a thin film material and filling a proper amount of the foam material into the foam material chamber; a step of putting the preformed core body into a mold according to a prescribed spatial arrangement and performing mold-in; and a step of integrally forming a fiber shell and a core structure. The preformed core body is formed by encapsulating with a layer of a fiber material, elevating the temperature of the mold cavity of the mold, and under an expansion pressure of the foam material, for forming a structural member shell (10) including at least two chambers (120), synchronizing a chamber wall (130) and a structure panel (110). The foam material in the preformed core body is expanded in the chamber wall (130) in a manner to form a multi-chamber type space structure orthogonal to the structure panel (110) and fills two chambers (120).SELECTED DRAWING: Figure 1

Description

Detailed Description of the Invention

[0001] (Technical field) The present invention is in the technical field of processing and manufacturing of fiber composites. FIELD OF THE INVENTION The present invention relates to composite materials, manufacturing processes and film materials for orthogonal structural members in multi-chambered fibers. [Background technology]

[0002] As the world's economic and technological levels gradually improve, people are placing greater demands on the strength, weight, and usability of various existing equipment and construction site materials.For example, the materials used for floors, side walls, and ceilings of workshops and houses, as well as the shells of construction vehicles and industrial equipment, are generally made of metal or non-metallic materials (such as plastic), which poses technical problems such as high workloads for on-site workers, potential safety hazards, and high installation difficulty.

[0003] Furthermore, they suffer from problems such as susceptibility to corrosion and deformation during use, insufficient strength, and poor earthquake resistance. To address these issues, manufacturers have developed alternatives using fiber composite materials. These fiber composite plate products offer many properties not found in existing metal or plastic plate materials, including excellent mechanical strength, high tensile strength, good corrosion resistance, and superior earthquake and impact resistance. However, structural and process constraints still pose several challenges to the use of existing fiber composite plate materials. For example, in blade and various turbine blade applications, existing fiber composite blades typically have solid, hollow, or segmented single-core structures, resulting in issues such as heavy weight, insufficient strength, poor earthquake resistance, high starting torque, and poor stability. Using the current state of technological development for wind turbine blades as an example, the advantages and disadvantages of various existing technologies are discussed in detail below.

[0004] Due to the pressure of worsening climate change and the promotion of environmental protection, people's need for clean energy will enter a stage of rapid development. According to the International Wind Energy Council, the world's wind power generation capacity is estimated to grow to 1,000 GW by 2022. Therefore, the international market for wind turbines is huge. Currently, the manufacturing cost of blades accounts for about 15% of the total cost of wind turbines. As a key component of wind turbines, blades will have a market share of $15 billion.

[0005] The basic wind power generation equipment uses a single blade structure. There was a problem that the strength was insufficient, and it was prone to breakage and malfunction. The following describes an embodiment of the present invention. Current design concepts rely on wind as the basic structure of the blade, resulting in drawbacks such as ineffective wind energy capture, high wind speeds (over 22 miles per hour), and high starting torque. The current mainstream design method uses semi-core airfoil-shaped blades. Each blade consists of two independently formed half-blades, which are bonded together via a foam material placed between the half-blades. A foam resin structure placed between each blade reduces vibration and noise and increases blade stability. However, this blade's divided blade structure has drawbacks such as a tendency for cracks to occur along the joints and insufficient mechanical strength. According to this study, a large-scale wind power generation system requires 100,000 semi-core blades. While repairs and replacements are currently possible, future maintenance costs will be prohibitive.

[0006] Meanwhile, against the backdrop of huge domestic energy consumption, some companies are aiming to develop low-wind speed, low-altitude wind energy solutions. For example, if the annual energy consumption cost of a household in the United States, such as heavy oil or gas, is approximately $15,000, and the installation cost of a currently commercially available 5kW wind power generation system is approximately $7,500, then utilizing wind energy would generate annual revenue of $7,500 through clean energy applications. For residential and commercial buildings, the market for low-speed wind power generation is huge, but currently there is no feasible solution.

[0007] In the United States, low-speed wind power generation equipment could be installed in approximately 75 million single-family homes, 30 million apartment buildings, and 6 million office buildings, resulting in potential market revenues of over 560 billion yen per year. There are approximately 75 million freestanding homes in the United States, with an average annual energy consumption of $2,400. If wind power generation equipment were installed to generate a profit of approximately 50% of the average annual energy consumption, or if a profit of $1,200 per year were calculated, the annual national income would be $180 billion in three years. For example, assuming 3 million apartment buildings with 20 units per building, average annual energy consumption of $20,000, and an annual income of $10,000, the market demand would be $300 billion per year. Low-wind-speed, low-altitude wind power generation can also be applied to commercial office buildings. With a low average energy consumption of $30,600, the potential market size is $86 billion per year, based on the size of 5.6 million commercial office buildings in the United States in 2012. Clean energy proposals will likely see governments around the world give a major push or mandate to use renewable energy in the near future.

[0008] Therefore, the development of wind turbine blades that are highly efficient, have low energy consumption and failure rates, and are suitable for generating electricity at low wind speeds and low altitudes is of great social and economic significance. Meanwhile, structural components such as plates with higher mechanical strength, better earthquake resistance, more perfect mechanical structures, and better strength-to-weight ratios (strength / weight), as well as corresponding processing technologies, have been developed, which will have important implications for socio-economic and technological progress. Summary of the Invention

[0009] In view of the technical problems of the prior art, the present invention provides a multi-chamber fiber composite cross-section structural member, a manufacturing method thereof, and a film material based on theoretical analysis and field practice. The multi-chamber fiber composite cross-section structural member can be used in applications such as blades for wind power generator systems of various sizes and wind speeds, and other plate materials that require high strength, thereby improving the mechanical strength of equipment, reducing equipment energy consumption, expanding the range of equipment applications, and improving the usability of existing equipment and facilities.

[0010] The present invention provides a method for manufacturing an orthogonal structural member in a multi-chamber fiber composite material as follows: The method for manufacturing an orthogonal structural member in a multi-chamber fiber composite material includes the following steps: preparing a preformed core by using a film material to form foam material chambers for accommodating the foam material and filling the foam material chambers with an appropriate amount of foam material; arranging the preformed cores prepared in the preformed core preparation step into a mold according to a predetermined spatial layout and sealing each preformed core with a layer of fiber material, thereby filling the mold with the preformed cores; and integrally forming a fiber shell and a core structure, by increasing the temperature of the die cavity and synchronously forming chamber walls and structural panels under the influence of the expansion pressure of the foam material to form a structural member shell with at least two chambers, while the foam material of the preformed core body expands to fill each chamber, forming a multi-chamber spatial structure in the chamber walls that is orthogonal to the structural panels.

[0011] Preferably, in the manufacturing process of the orthogonal structural member in the multi-chamber fiber composite material provided by the present invention, the film material can be various layers, such as optical film, composite film, superconducting film, polyester film, nylon film, plastic film, fiber film, wax paper film, film made of foam material, etc. Any film that has good formability and can be used to prepare a preformed core of an appropriate shape according to the specific structure of the orthogonal structural member in the multi-chamber fiber composite material can be used in the step of preparing a preformed core.

[0012] More preferably, the film material used in the manufacturing process for the orthogonal structural member of the multi-chamber fiber composite material of the present invention comprises a wax film resin layer, an adhesive resin layer, and a foam polymer resin blend layer, the foam polymer resin blend layer being coated with the foam polymer resin blend, and the foam polymer resin blend is composed of a foam material with a volume fraction of 65% or more. The foam polymer resin blend is preferably a resin gel containing a hydrocarbon solvent such as ethylene-vinyl acetate copolymer, and is used to prevent deterioration and shrinkage of the foam material during the heat-curing process of the fiber material layer. Film materials containing a wax film resin layer, an adhesive resin layer, and a foam polymer resin blend layer not only have excellent molding properties, but can also be used to manufacture preformed cores of appropriate shapes for the specific structure of the orthogonal structural member of the multi-chamber fiber composite material, preventing decomposition and shrinkage of the foam material during the heat-curing process of the fiber material layer.

[0013] More preferably, the film material used in the manufacturing process of the orthogonal structural member in the multi-chamber fiber composite material provided by the present invention comprises a pressure-sensitive adhesive layer and a water-insoluble wax film layer with a polymer adhesive, the pressure-sensitive adhesive layer comprises a solvent carrier, a foaming material, a water-insoluble expandable pressure-sensitive adhesive, and a temperature-sensitive molding resin, and the volume fraction of the foaming material relative to the solvent carrier is not less than 50%.

[0014] Preferably, in the manufacturing process of the orthogonal structural member in the multi-chamber fiber composite material, the monomer particles of the foam have a microcapsule structure, and the microcapsule structure comprises a capsule shell made of a plastic material, and the orthogonal structural member in the multi-chamber fiber composite material provided by the present invention is as follows: The orthogonal structural member in the multi-chamber fiber composite material comprises a shell, the shell comprising a plurality of structural panels and at least two chambers arranged between the structural panels, a chamber wall arranged between each pair of adjacent chambers and perpendicular to the structural panels, the shell and the chamber wall made of a carbon fiber material or a glass fiber material, and the chamber has a foamed plastic core therein, and the structural panels, chambers, chamber wall and core are integrally molded by a thermoforming process of the fiber material and the foamed plastic.

[0015] As a preferred orthogonal structural member in the multi-chamber fiber composite material of the present invention, the structural panel, chamber, chamber wall and core are integrally formed through the manufacturing process of the orthogonal structural member in the multi-chamber fiber composite material described in any of the above technical methods.

[0016] A preferred orthogonal structural member in the multi-chamber fiber composite material of the present invention is a blade structure in which the orthogonal structural member in the multi-chamber fiber composite material is a blade panel.

[0017] Preferred orthogonal structural members in the multi-chamber fiber composite material of the present invention include those in which the shell is fan-shaped and the chambers extend radially of the shell and are evenly distributed circumferentially of the shell, or those in which the chambers extend circumferentially of the shell and are evenly distributed radially of the shell.

[0018] A preferred orthogonal structural member in the multi-chamber fiber composite material of the present invention is a plate-like structure in which the structural panel is a plate-like panel and the chambers are distributed in a honeycomb pattern or an orthogonal or anisotropic lattice or band pattern.

[0019] A preferred orthogonal structural member in the multi-chamber fiber composite material of the present invention is one in which a core material is filled in the chamber.

[0020] A preferred orthogonal structural member in the multi-chamber fiber composite material of the present invention is one in which the shell is a closed shell.

[0021] The film material used in processing orthogonal structural members in the multi-chamber fiber composite material of the present invention comprises a wax film resin layer, an adhesive resin layer, and a foaming material polymer resin mixture layer, the foaming material polymer resin mixture layer being coated with the foaming material polymer resin mixture, the foaming material polymer resin mixture being made of a foaming material at a volume fraction of 65% or more. Alternatively, the film material comprises a pressure-sensitive adhesive layer and a water-insoluble wax film layer with a polymer adhesive, the pressure-sensitive adhesive layer containing a solvent carrier, a foaming material, a water-insoluble expandable pressure-sensitive adhesive, and a heat-sensitive molding resin, the foaming material being uniformly distributed in the solvent carrier, and the volume fraction of the foaming material relative to the solvent carrier being not less than 50%.

[0022] The orthogonal structural member in the multi-chamber fiber composite material provided by the present invention adopts an orthogonal spatial structure within the multiple chambers and employs a thermoforming process to integrate the fiber shell and core structure, thereby achieving the following main technical effects: the orthogonal structural member has higher strength, a better strength-to-weight ratio, better stability and impact resistance, and a more perfect spatial structure. Taking wind turbine blades as an example, the multi-chamber fiber composite blade and its processing technology provided by the present invention solves the technical problems in the prior art and promotes breakthroughs in the fields of wind power generation and related technologies.

[0023] First, it overcomes the technical limitations of the prior art split-band blades and adopts high-strength, lightweight, large-area fiber blades. While maintaining the same power generation output, it significantly reduces starting torque. The wind-receiving area is dramatically expanded, allowing it to be used in both high-speed and low-speed wind environments, effectively improving power generation efficiency.

[0024] Second, the present invention overcomes the technical limitations of the prior art split-core assembly technology by adopting a multi-chamber integral orthogonal molding technology solution, which incorporates multiple filling cores and multiple chamber walls. The blade manufacturing process proposed herein integrates the fiber shell and plastic core into a single unit. This effectively increases the overall mechanical strength of the blade, significantly reduces vibration and noise during blade rotation, and improves blade stability during operation. It also effectively improves the airtightness of the connection between the blade fiber shell and the filling core, improving overall blade reliability. Meanwhile, the multi-chamber integral molding technology also realizes a large-area blade structure, improving power generation efficiency and reducing starting torque.

[0025] Third, the present application overcomes the technical limitation of the non-orthogonal arrangement between the plastic core and the blade panel in the prior art. The multi-chamber spatial structure of the panel, in which the chamber walls are perpendicular or perpendicular to the core, can be processed while the fiber shell and multi-chamber are being molded. This spatial structure is theoretically the strongest and most perfect structure, which is most conducive to improving the pressure resistance of the blade and reducing vibration and operating noise. Since the orthogonal structural members and corresponding manufacturing methods for the multi-chamber fiber composite material provided by this application do not exist in the prior art, the technical solution disclosed by this application fills a gap in the market and solves the technical problems existing in the prior art.

[0026] The present invention has obvious technical progress and social, economic and environmental protection significance. In order to make the technical solution and technical effect of the present invention clearer and more clear, the orthogonal structural member in the multi-chamber fiber composite material disclosed in the present invention and the corresponding manufacturing process will be described in detail below with the accompanying drawings and specific embodiments.

[0027] In order to make the technical solutions and technical effects of the present invention clearer and more obvious, the orthogonal structural members in the multi-chamber fiber composite material disclosed in the present invention and the corresponding manufacturing processes will be described in detail below in conjunction with the accompanying drawings and specific embodiments. [Brief explanation of the drawings]

[0028] [Figure 1] 1 is an overall perspective view of a blade structure according to a first embodiment. [Figure 2] 3 is a cross-sectional view taken along the line AA in FIG. 2. [Figure 3] 1 is a schematic diagram of a blade manufacturing process according to a first preferred embodiment. [Figure 4] FIG. 10 is an overall perspective view of a blade structure according to a second embodiment. [Figure 5] FIG. 10 is a schematic view of a honeycomb chamber according to a third embodiment. [Figure 6] FIG. 2 is an explanatory diagram of an internal orthogonal structure in the present application. [Figure 7] FIG. 1 is a schematic diagram of a three-layer film material structure. [Figure 8] FIG. 1 is a two-layer schematic diagram of a film material structure. DETAILED DESCRIPTION OF THE INVENTION

[0029] Referring to Figures 1 and 2, an application example of the first preferred embodiment of the present application, which discloses a fan-shaped multi-chamber fiber composite blade including a closed shell 10, will be described. The shell 10 includes two structural panels 110 (i.e., blade panels). When assembled into a wind turbine rotor, the two structural panel blades 110 form the front and rear panels of the blade, respectively. The overall shape of the shell 10 is fan-shaped, and its surface area is 6 to 10 times that of existing strip-shaped blades of the same length, which is beneficial for greatly increasing the blade's wind-receiving area. Five cone-shaped chambers 120 are provided inside the shell 10, extending radially along the shell 10 and uniformly distributed circumferentially along the shell 10. Of these five chambers 120, every two adjacent chambers 120 have chamber walls 130 perpendicular to the inner panel structure 110. The shell 10 and the chamber wall 130 are both made of carbon fiber composite material, and the chamber 120 is provided with a core made of foamed plastic 20, which fills the chamber 120. The structural panel 110, the chamber 120, the chamber wall 130 and the core 20 are integrally formed by thermoforming processing of fiber material and foamed plastic as shown in Figure 3, i.e., the manufacturing method of the orthogonal structural part in the multi-chamber fiber composite material claimed in the present application.

[0030] Referring to FIG. 3, the manufacturing process for a cross-sectional structural member in a multi-chamber fiber composite material provided herein includes a front core plastic body preparation step in which a foam material chamber is formed using a thin film material to accommodate a foam material and an appropriate amount of foam material is filled into the foam material chamber to prepare a front core plastic body; and a front core plastic body preparation step in which the foam material chamber is filled with foam material to prepare a front core plastic body. The thin film material may be any film with good formability that can be used to prepare a pre-core plastic body of an appropriate shape depending on the specific structure of the cross-sectional structural member in the multi-chamber fiber composite material, such as an optical film, composite film, superconducting film, polyester film, nylon film, plastic film, fiber film, wax paper film, or foam material film. This pre-core plastic body preparation step can be applied. The thin film material used in this embodiment is a special thin film material uniquely invented by the inventors, and, as shown in FIG. 7, includes a wax film resin layer, an adhesive resin layer, a foam material / polymer resin mixed layer, and a foam material / polymer resin. The mixed layer is formed by applying a foam material / polymer resin mixture. The foamed material polymer resin mixture contains a foamed material and a gel-like polymer resin, with the volume fraction of the foamed material being 65% or more. Specifically, the gel-like polymer resin may be a resin gel containing a hydrocarbon solvent such as ethylene-vinyl acetate copolymer, or a floor adhesive or caulking adhesive. By incorporating a wax film resin layer, an adhesive resin layer, and a foamed material polymer, the thin film material of the resin mixture layer not only has good moldability, but can also be formed into a pre-core resin body of an appropriate shape depending on the specific structure of the orthogonal structural member in a multi-cell fiber composite material. Furthermore, deterioration and shrinkage of the foamed material in the fiber material layer can be prevented during heat curing.

[0031] Because the hot-melt, molding, and curing processes for the fiber material layers often take tens of minutes to several hours, the ideal multi-chamber fiber orthogonal spatial architecture cannot be achieved in composites unless the foam used in the pre-core plastic has the ability to prevent core deterioration and shrinkage. Based on practical observations and theoretical analysis, the optimal technical parameters for the foamed polymer-resin composite layer of the thin-film material are thermal conductivity 3 W / mK, heat capacity 1 J / gK, dielectric constant 200 VAC / mil, operating temperature 68-395°F, and dissipation factor 0.002 / 100 kHz. In some improved embodiments, a special thin-film material independently invented by the inventors may be used in the fabrication of the orthogonal structure in the multi-chamber fiber composite provided by this invention. See Figure 8 for an example of a viscous adhesive layer with a polymer adhesive, a water-insoluble wax film layer, and a viscous adhesive layer coated on the water-insoluble wax foam layer with a polymer adhesive. The adhesive contact layer comprises a solvent carrier, a foam material, a water-insoluble expandable viscous polymer adhesive, and a heat-sensitive molding resin. The solvent carrier is a resin gel, floor adhesive, caulking agent, etc., and the foam material is uniformly dispersed in the solvent carrier, with a volume fraction of the foam material in the solvent carrier of 50% or more. The adhesive-coated thin film material and the water-insoluble wax foam layer with polymer adhesive prevent deterioration and shrinkage of the foam material during heat curing of the fiber material layer, enabling a complete multi-chamber orthogonal spatial architecture to be achieved in the core.

[0032] In the pre-core plastic body molding step, the pre-core plastic bodies prepared in the pre-core plastic body preparation step are placed into a mold according to a predetermined or required spatial layout (in this embodiment, along the diameter, extending uniformly in the circumferential direction) and completely encapsulated with a layer of fiber material. Specifically, a layer of fiber material is placed in a mold, and the pre-core plastic bodies prepared in the pre-core plastic body preparation step are placed in the mold in the spatial arrangement shown in Figure 3, and the pre-core plastic bodies are completely encapsulated with the layer of fiber material. Alternatively, the pre-core plastic bodies can be completely encapsulated with the layer of fiber material according to the spatial arrangement shown in Figure 3, and the encapsulated pre-core plastic bodies can be loaded into the mold together with the layer of fiber material. The step of molding the fiber shell and core architecture all-in-one: the temperature of the mold cavity is raised and lowered according to the melting temperature and curing temperature of the fiber material layer and the foam material, and under the action of the expansion pressure of the foam material, the chamber walls 130 and the structural panel 110 are synchronously molded to form a shell 10 consisting of multiple chamber cores 120, and at the same time, the foam material of the pre-core plastic body is filled into each core 120 to form the chamber walls 130 perpendicular to the multi-chamber spatial structure of the structural panel 110.

[0033] In this application, any available foam plastic material can be used as the core material as long as it can maintain a certain pressure before the carbon fiber or glass fiber material hardens. The chamber wall 130 formed during the thermoforming process is perpendicular to the structural panel 110, so it can be applied to the technical solution provided by this application to achieve the desired technical effect. For example, in this preferred embodiment, the monomer particle size is 10-30 microns, the monomer density is 1.03 g / cm3, and the expansion coefficient is 50-70. The foam material is used as the core material, achieving a perfect synchronous molding effect between the fiber shell and the core structure. Because the foam material used in this preferred embodiment can maintain a certain pressure before the carbon fiber or glass fiber material hardens (specifically, it can maintain a pressure strength of 7 kg / cm2 or more before 70°C), the chamber wall 130 formed during the thermoforming process can be perpendicular to the structural panel 110. If the foaming material used cannot maintain a certain pressure before the fiber material hardens, the chamber wall will not be perpendicular or at right angles to the structural panel, which will affect the technical performance of the finished product, such as wind force and starting torque, low-speed wind capture efficiency, and other technical parameters.

[0034] Preferably, the monomer particles of the foam material have a microcapsule structure including a capsule shell made of a plastic material, and the foam material is encapsulated in the capsule shell. Because the microcapsule particles are uniformly dispersed and the foam material is rapidly released and concentrated after melting, the microcapsule-structured foam material has technical properties such as uniform heating, fast heat conduction, and good foaming synchronization. As the scale of wind power generation expands and the usage environment changes, wind power blades also need to change in volume and structure to adapt to changes in scale and usage environment, placing increasing demands on blade research institutes and manufacturers. While different from the design concept of conventional strip blades, the inventors have discovered that high-strength, lightweight fan blades not only improve wind energy capture efficiency but also enable applications at low wind speeds, low altitudes, and low torque.

[0035] Assuming the blade lengths are equal, the effective wind-receiving area of ​​the fan-shaped multi-chamber fiber composite blade provided by the present invention is 6-10 times that of a conventional rectangular blade. In the prior art, for example, a conventional semi-core wind turbine with a 5kW output and a blade length of 9 feet has a blade surface area of ​​approximately 15 square feet. If the fan-shaped multi-chamber fiber composite blade provided by the present invention is used under the same assumption of a 15 square foot surface area, the wind blade length would be only 2.5 feet. It has been practically confirmed that in a 5kW generator set, the composite multi-chamber fiber fan blade provided by the present invention can provide a wind speed of 11-13 miles per hour, a wind speed of 3000 rpm at 1000-1600 rpm, a very low starting torque of 0.1 NM at a wind speed of 3 mph, and a total blade weight of only 15 kg. Therefore, the multi-chamber fiber composite orthogonal blade provided by the present invention can still maintain continuous energy production during normal operation at low wind speeds.

[0036] The present invention provides a multi-chamber fiber composite blade with an orthogonal structure, allowing for the creation of a blade with a multi-chamber structure and a core wall perpendicular to the blade panel. The multi-chamber wall and orthogonal structure of the fiber composite blade provide the strongest fiber composite leaf structure with the best strength-to-weight ratio. For example, in an application with a total weight of 685 g, the blade's thickest point is 7 mm and its thinnest point is 3 mm.

[0037] In the multi-chamber fiber composite structure and its manufacturing method provided by the present invention, the multi-chamber structure and fiber shell are integrally formed by thermoforming the fiber material and the foam plastic. The foam used to form the core can maintain a certain pressure before the carbon fiber material or glass fiber material solidifies, so that multiple chamber walls perpendicular to the blade panel can be simultaneously formed during the thermoforming process. The various fiber composite processing techniques in the prior art cannot produce the fiber shell structure of the orthogonal blade in the multi-chamber fiber composite material provided by the present invention, nor the core structure in which the panels and chamber walls are perpendicular to each other. Furthermore, the resulting strip blades cannot reach the mechanical strength and strength-to-weight ratio of the orthogonal blade in the multi-chamber fiber composite material provided by the present invention. In the orthogonal blade in the multi-chamber fiber composite material provided by the present invention, the blade panels at the chamber walls are perpendicular to each other, so that the large-area, ultra-thin blade panels have sufficient strength to withstand wind-generated pressure.

[0038] Prior art fiber thermoforming wind turbine products have adopted a single-function semi-core blade and a foamed plastic filling structure to reduce turbine vibration and noise and improve stability. Over the past few decades, there has been little innovation in the fiber thermoforming process and blade structure. As a result, wind power generation in recent years has had low overall efficiency, relatively large input and output, and new application requirements that make it inapplicable to low wind speeds and low altitudes. This invention uses a high-density, lightweight foamed plastic core and a large-area fan-shaped blade with a multi-chamber orthogonal internal space structure. This effectively reduces blade vibration and noise during high-speed operation, improves blade stability, and provides high wind energy capture and low starting torque, making it suitable for widespread use in residential and commercial power generation environments.

[0039] Preferred embodiments of both Another use of blades for wind turbines FIG. 4 shows another embodiment of an orthogonal structural member in a multi-chamber fiber composite material of the present invention and a manufacturing process thereof. In a preferred embodiment, the chamber 120 in the shell 10 and the core 20 filled in the chamber 120 both have a ring structure. The chamber 120 extends along the circumferential direction of the shell 10 and also extends along the radial direction of the shell 10, where the chambers 120 are evenly spaced. Due to the structural change of the blade, the shape of the foam material chamber used to hold the foam material in the pre-core plastic body preparation step also has a ring structure, and in the pre-core plastic body molding step, the pre-core plastic also needs to be evenly spaced along the radial direction and spatially spread along the circumferential direction. Other aspects are the same as those of the first preferred embodiment, and those skilled in the art can refer to the embodiments.

[0040] Example 3, Preferred Embodiment: Another preferred embodiment of the present invention discloses a high-strength, lightweight, internal orthogonal plate structure for use in plants, chambers, and other applications. This structure may be a rectangular structural component, flat plate, curved plate, or curved panel, and can be widely used to make various plates, such as floors, exterior walls, ceilings, and shell structures for ships, vehicles, homes, and factory facilities. See Figure 5, where multiple chambers within the shell are honeycomb structures. In other embodiments, it is also possible to develop other multi-chamber spatial architectures, such as orthogonal or diagonal grid structures.

[0041] The chambers are evenly arranged in the shell, and the chamber walls are perpendicular to the shell panels. To accommodate structural changes, in the pre-core plastic body preparation step, the foam material chamber used to hold the foam material also has a honeycomb unit structure, and in the pre-core plastic body molding step, the pre-core plastic body needs to be arranged according to the spatial structure of the three-dimensional honeycomb and sealed with a fiber material layer. Other aspects are basically the same as in preferred embodiment 1 and preferred embodiment 2, and those skilled in the art can refer to these embodiments.

[0042] Preferred Embodiment 4: According to the present application, when using conventional wind turbine blades or blade strips, the blades will undoubtedly achieve very beneficial technical effects by incorporating the multi-chamber fiber composite material according to the second preferred embodiment disclosed in the rotor style of the orthogonal blade embodiment into the turbine. One of the simplest and most feasible technical solutions is to provide the existing air knife blade with a fiber composite material having a multi-chamber orthogonal structure, which not only provides the various advantages already described in this application, but also allows the existing air knife blade to be perfectly adapted to various supporting equipment installed. Therefore, the manufacturing process of the orthogonal structural parts of the multi-chamber fiber composite material disclosed in this application and the direct application of the corresponding orthogonal structural parts of the multi-chamber fiber composite material to the blade of a conventional air knife are also within the scope of protection of this application.

[0043] It should be noted that most of the various embodiments and modifications introduced above are based on the application of planar structural panels. However, the solution provided by the present application is not limited to the application of planar structural panels. See Figure 6, which illustrates an irregularly curved structural member. The irregularly curved structural member includes an irregularly curved structural panel. The irregularly curved structural member also has the protection claimed in the present application and has the technical characteristics of an orthogonal structural section within a multi-chamber fiber composite. Therefore, the understanding of internal orthogonality described in the present application is not limited to the vertical structure of a planar structural panel, but also includes the orthogonal structure in three-dimensional space of an irregularly curved structural panel.

[0044] With reference to the accompanying drawings of the detailed embodiments of the present invention described above, it should be noted that the scope of the present invention is preferably not limited to the above-mentioned embodiments. The specific configurations disclosed in the accompanying drawings are relatively the present invention according to the preferred embodiments, and those skilled in the art may develop other embodiments based on them. Furthermore, simple modifications or equivalent replacements made within the scope of the innovative concept of the present invention are included in the present invention and fall within the protection scope of the present invention. [Explanation of symbols]

[0045] A*Adhesive layer B - Water-insoluble wax film layer with polymer adhesive 1-Wax film resin layer 2-Adhesive resin layer 3-Foam material polymer resin mixture layer 10 shells 20 cores 110 structural panels 120 chambers 130 Chamber Wall

Claims

1. A method for manufacturing an orthogonal structural member in a multi-chamber fiber composite material, comprising: forming a foam material chamber using a thin film material to contain a foam material, and filling the foam material chamber with an appropriate amount of the foam material to prepare a preformed core; placing the preformed core body in a mold according to a predetermined spatial arrangement and performing molding; and forming the fiber shell and the core structure integrally; the preformed core is sealed with a layer of fibrous material; increasing the temperature of the mold cavity and synchronously forming chamber walls (130) and structural panels (110) under the expansion pressure of the foam material to form a structural member shell (10) comprising at least two chambers (120); The foam material within the preformed core expands to fill the two chambers (120) to form a multi-chamber structure at the chamber walls (130) perpendicular to the structural panel (110); The thin film material includes a wax film resin layer (1), an adhesive resin layer (2), and a foamable material polymer resin mixture layer (3); The foamable material polymer resin mixture layer (3) is formed by coating with a foamable material polymer resin mixture and contains a foamable material having a volume fraction of 65% or more. A method for manufacturing an orthogonal structural member.

2. A method for manufacturing an orthogonal structural member in a multi-chamber fiber composite material, comprising: forming a foam material chamber using a thin film material to contain a foam material, and filling the foam material chamber with an appropriate amount of the foam material to prepare a preformed core; placing the preformed core body in a mold according to a predetermined spatial arrangement and performing molding; and forming the fiber shell and the core structure integrally; the preformed core is sealed with a layer of fibrous material; increasing the temperature of the mold cavity and synchronously forming chamber walls (130) and structural panels (110) under the expansion pressure of the foam material to form a structural member shell (10) comprising at least two chambers (120); The foam material within the preformed core expands to fill the two chambers (120) to form a multi-chamber structure at the chamber walls (130) perpendicular to the structural panel (110); The thin film material comprises a tacky adhesive layer (A*) and a water-insoluble wax film layer (B) having a polymer adhesive; the viscous adhesive layer (A*) comprises a solvent carrier, a foamable material, a water-insoluble expandable viscous polymer adhesive, and a thermo-molding resin; the foamable material is uniformly dispersed in the solvent carrier; The method for manufacturing an orthogonal structural member, wherein the volume fraction of the expandable material to the solvent carrier is 50% or greater.

3. the monomer particles of the foam material have a microcapsule structure including a capsule shell formed of a plastic material; The method for manufacturing an orthogonal structural member according to claim 1 or 2, wherein the foam material is encapsulated in the capsule shell.

4. A thin film material used in the manufacturing process of orthogonal structural members in multi-chamber fiber composite materials, It comprises a wax film resin layer (1), an adhesive resin layer (2), and a foamable material polymer resin mixture layer (3), The foamable material polymer resin mixture layer (3) is formed by coating with a foamable material polymer resin mixture, A thin film material, wherein the foamable material polymer resin mixture contains a foamable material having a volume fraction of 65% or more.

5. A thin film material used in the manufacturing process of orthogonal structural members in multi-chamber fiber composite materials, a tacky adhesive layer (A*) and a water-insoluble wax film layer (B) having a polymer adhesive, the viscous adhesive layer (A*) comprises a solvent carrier, a foamable material, a water-insoluble expandable viscous polymer adhesive, and a thermo-molding resin; the foamable material is uniformly dispersed in the solvent carrier; A thin film material, wherein the volume fraction of the expandable material to the solvent carrier is 50% or greater.

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