Vacuum infusion molding method for wind turbine blade component

Abstract

The present application relates to a vacuum infusion molding method for a wind turbine blade component. The vacuum infusion molding method comprises: providing a blade mold; laying a fiber reinforcing layer on the blade mold; laying a peel ply fabric on the fiber reinforcing layer; laying a flow guide mesh on the peel ply fabric; laying a partition layer on a local area of the flow guide mesh, the partition layer comprising a bubble breakup layer and a heat insulation layer, and the bubble breakup layer being connected to the heat insulation layer; providing a flow guide pipe on the partition layer, the flow guide pipe being arranged on the side of the partition layer facing away from the flow guide mesh; laying a vacuum bagging film; using a vacuum pump to extract air to form a negative pressure in the vacuum bagging film; and providing an infusion material, the infusion material being injected through the flow guide pipe, such that the infusion material infiltrates the fiber reinforcing layer and then undergoes curing treatment, so as to form a blade component.

Description

Vacuum casting molding method for wind turbine blade components

[0001] Cross-references to related applications

[0002] This application claims priority to Chinese Patent Application No. 202410961740.5, filed on July 17, 2024, entitled “Vacuum Injection Molding Method for Wind Turbine Blade Components”, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to the field of wind power generation, and in particular to a vacuum injection molding method for wind turbine blade components. Background Technology

[0004] In recent years, wind energy, as a large-scale commercial clean and renewable energy source, has received widespread attention from various countries. With the rapid development of the wind power industry and the increasing size of wind turbine blades, these blades are the core components of wind turbines for capturing wind energy, and their operational status directly affects the efficiency of wind energy utilization. Currently, wind turbine blades are typically manufactured using vacuum injection molding. Therefore, improving the quality of wind turbine blades manufactured using vacuum injection molding to ensure the structural safety of large wind turbine blades has become a key research focus. Summary of the Invention

[0005] This application provides a vacuum injection molding method for wind turbine blade components, which can ensure that the molded blade components are not prone to whitening, and at the same time, the number of internal air bubbles is small or there are no air bubbles.

[0006] This application provides a vacuum casting molding method for wind turbine blade components, which includes:

[0007] Provide blade molds;

[0008] A fiber reinforcement layer is laid on the blade mold;

[0009] A release liner is laid on the fiber-reinforced layer;

[0010] Lay a flow guide net on the release fabric;

[0011] A partition layer is laid on a local area of ​​the flow guide net. The partition layer includes a bubble dispersion layer and a heat insulation layer, and the bubble dispersion layer and the heat insulation layer are connected.

[0012] A flow guide pipe is installed on the partition layer, and the flow guide pipe is located on the side of the partition layer opposite to the flow guide net;

[0013] Lay out vacuum bags;

[0014] Use a vacuum pump to evacuate air and create a negative pressure inside the vacuum bag membrane;

[0015] An infusion material is provided and injected through a guide tube. The infusion material impregnates the fiber reinforcement layer and is then cured to form the blade component.

[0016] In the vacuum casting molding method for wind turbine blade components according to this application embodiment, a partition layer is provided on one side of the guide net, and a guide pipe is provided on one side of the partition layer. The guide pipe is used to introduce a relatively high-temperature casting material. The casting material discharged from the guide pipe releases a large amount of heat. The partition layer can block the casting material discharged from the guide pipe. Part of the casting material discharged from the guide pipe can pass through the partition layer, the guide net, and the release cloth and flow towards the fiber reinforcement layer, while part can flow to the area outside the partition layer and pass through the guide net and the release cloth and flow towards the fiber reinforcement layer. The partition layer can effectively disperse the casting material discharged from the guide pipe, reducing the possibility that the casting material discharged from the guide pipe will continuously release a large amount of heat at the outlet of the guide pipe and form heat accumulation.

[0017] In addition, the heat insulation layer in the partition can effectively isolate the infusion material at the guide tube from the fiber reinforcement layer below. During the curing stage of the infusion material, the heat released by the infusion material at the guide tube is not easily conducted to the fiber reinforcement layer, reducing the possibility that the curing rate or curing effect of the infusion material below the guide tube may be affected by local high temperature, resulting in local whitening problems in the molded blade component.

[0018] Furthermore, during the flow of the injection material through the interlayer, the bubble dispersion layer within the interlayer can disperse and adsorb the bubbles carried in the injection material, thereby effectively reducing the number of bubbles in the injection material and the blade components. Simultaneously, during the curing process of the injection material at the fiber reinforcement layer, small bubbles in the injection material can continuously aggregate to form larger bubbles. These larger bubbles can rise towards the interlayer. After entering the bubble dispersion layer, the layer can disperse the larger bubbles into smaller bubbles and adsorb these smaller bubbles, causing them to remain within the bubble dispersion layer.

[0019] Therefore, the wind turbine blade components formed by the vacuum injection molding method of this application are less prone to localized whitening, and the number of air bubbles inside the blade components is small or non-existent. The wind turbine blade components formed by the vacuum injection molding method of this application have a high yield and good product quality, effectively reducing the possibility of rework, repair, or product scrap.

[0020] In some feasible methods, an insulation layer is provided on one side of the bubble dispersion layer; or, insulation layers are provided on opposite sides of the bubble dispersion layer.

[0021] In some feasible ways, the bubble dispersion layer and the insulation layer are bonded together; or, the bubble dispersion layer and the insulation layer are integrally formed.

[0022] In some feasible ways, the orthographic projection of the guide tube lies within the orthographic projection of the partition along the thickness direction of the partition.

[0023] In some feasible methods, the spacer extends beyond the guide tube by a dimension greater than or equal to 1 mm.

[0024] In some feasible implementations, a partition layer is provided in regions where the number of fiber reinforcement layers is greater than or equal to 40; and / or,

[0025] A fiber reinforcement layer is laid on the blade mold, a core material is laid on the fiber reinforcement layer, and a fiber reinforcement layer is laid on the core material. The spacers are set corresponding to the core material.

[0026] In some feasible ways, the flow guide tube and the partition are connected by at least one of adhesive bonding and wire bonding; or, the partition and the flow guide tube are integrally formed.

[0027] In some feasible embodiments, the bubble dispersion layer includes a first fiber layer woven from warp and weft threads; or, the bubble dispersion layer includes a first fiber layer and a second fiber layer, wherein the first fiber layer is woven from warp and weft threads, the second fiber layer is disposed between the two first fiber layers, and the second fiber layer supports the first fiber layer.

[0028] The insulation layer is connected to the first fiber layer.

[0029] In some feasible embodiments, the guide tube includes a first outlet and a second outlet, the first outlet being disposed facing the partition, and the second outlet being disposed on two opposite end faces along the axial direction of the guide tube.

[0030] In some feasible implementations, the insulation layer includes a first through hole that extends through the insulation layer along the thickness direction of the insulation layer.

[0031] In some feasible implementations, the cross-sectional area of ​​the first through hole is S1, and the projected area of ​​the insulation layer along the thickness direction of the interlayer is S2, wherein the value of S1 / S2 ranges from 0.000049 to 0.008.

[0032] In some feasible ways, the insulation layer is rectangular in shape, and the first through hole is a rectangular or circular hole.

[0033] In some feasible embodiments, the bubble dispersion layer includes a second through-hole that extends through the bubble dispersion layer along the thickness direction of the interlayer.

[0034] In some feasible implementations, the cross-sectional area of ​​the second through hole is S11, and the projected area of ​​the bubble dispersion layer along the thickness direction of the interlayer is S22, wherein the value of S11 / S22 ranges from 0.00000785 to 0.00003.

[0035] In some feasible implementations, the bubble dispersion layer is rectangular in shape, and the number of second through holes is two or more, with at least two second through holes being interconnected.

[0036] In some feasible ways, the thickness of the insulation layer ranges from 3 mm to 10 mm; and / or, the thickness of the bubble dispersion layer ranges from 1 mm to 10 mm.

[0037] In some feasible ways, a porous release membrane is laid on the release fabric, and a flow guide mesh is laid on the porous release membrane. Attached Figure Description

[0038] The features, advantages, and technical effects of exemplary embodiments of this application will now be described with reference to the accompanying drawings.

[0039] Figure 1 is a schematic diagram of the structure of a wind turbine generator set provided in some embodiments of this application;

[0040] Figure 2 is a schematic flowchart of a vacuum injection molding method for wind turbine blade components provided in some embodiments of this application;

[0041] Figure 3 is a schematic diagram of the vacuum injection molding process for wind turbine blade components provided in some embodiments of this application;

[0042] Figure 4 is a partial structural schematic diagram of the partition provided in some embodiments of this application;

[0043] Figure 5 is a partial structural schematic diagram of the vacuum injection molding process for wind turbine blade components provided in some embodiments of this application;

[0044] Figure 6 is a partial structural schematic diagram of the partition provided in some embodiments of this application;

[0045] Figure 7 is a partial structural schematic diagram of the connection state between the partition and the guide tube provided in some embodiments of this application;

[0046] Figure 8 is a partial structural schematic diagram of the vacuum injection molding process for wind turbine blade components provided in some embodiments of this application;

[0047] Figure 9 is a partial structural schematic diagram of the vacuum injection molding process for wind turbine blade components provided in some embodiments of this application;

[0048] Figure 10 is a partial structural schematic diagram of the guide tube provided in some embodiments of this application;

[0049] Figure 11 is a partial structural schematic diagram of the partition provided in some embodiments of this application;

[0050] Figure 12 is a partial structural schematic diagram of the partition provided in some embodiments of this application;

[0051] Figure 13 is a partial structural schematic diagram of the heat insulation layer provided in some embodiments of this application;

[0052] Figure 14 is a partial structural schematic diagram of the heat insulation layer provided in some embodiments of this application;

[0053] Figure 15 is a partial structural schematic diagram of the bubble dispersion layer provided in some embodiments of this application.

[0054] The accompanying drawings are not necessarily drawn to scale.

[0055] Explanation of reference numerals in the attached drawings: 100, Wind turbine generator set; 110, Tower; 120, Nacelle; 130, Wind rotor; 131, Hub; 132, Blade; 10, Blade mold; 20, Fiber reinforcement layer; 30, Release cloth; 40, Flow guide net; 50, Partition; 51, Insulation layer; 51a, First through hole; 52, Bubble dispersion layer; 52a, Second through hole; 521, First fiber layer; 522, Second fiber layer; 60, Flow guide pipe; 61, First liquid outlet; 62, Second liquid outlet; 70, Vacuum bag membrane; 80, Porous isolation membrane; 90, Core material; Z, Thickness direction. Detailed Implementation

[0056] 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 described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0057] Unless otherwise defined, the technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used in the specification of this application is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms "comprising" and "having," and any variations thereof, in the specification, claims, and foregoing drawings of this application are intended to cover non-exclusive inclusion. The terms "first," "second," etc., in the specification, claims, or foregoing drawings of this application are used to distinguish different objects, rather than to describe a specific order or hierarchy.

[0058] In this application, the reference to "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment that is mutually exclusive with other embodiments.

[0059] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "attachment" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication 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.

[0060] In the embodiments of this application, the same reference numerals denote the same components, and for the sake of brevity, detailed descriptions of the same components are omitted in different embodiments. It should be understood that the thickness, length, width, and other dimensions of various components in the embodiments of this application shown in the accompanying drawings, as well as the overall thickness, length, width, and other dimensions of the integrated device, are merely illustrative and should not constitute any limitation on this application.

[0061] In this application, "multiple" means two or more (including two).

[0062] Figure 1 schematically shows the structure of a wind turbine generator set 100. Referring to Figure 1, an embodiment of this application provides a wind turbine generator set 100.

[0063] The wind turbine generator set 100 includes a tower 110, a nacelle 120, and a rotor 130. The nacelle 120 is located at the top of the tower 110. The rotor 130 includes a hub 131 and blades 132. The blades 132 are connected to the hub 131. The hub 131 is connected to the main shaft of the nacelle 120. The blades 132 can generate torque under wind power. The blades 132 and the hub 131 drive the main shaft of the nacelle 120 to rotate, thereby converting wind energy into mechanical energy. The main shaft of the nacelle 120 can be connected to the rotor of the generator, thereby converting mechanical energy into electrical energy. The blade components can be manufactured using vacuum casting. Two blade components can be joined to form a complete blade 132.

[0064] In related technologies, vacuum infusion molding is used to process blade components. During the molding process, a fiber reinforcement layer, a release cloth, and a flow guide net are laid on the blade mold. A flow guide pipe is used above the flow guide net to deliver a high-temperature infusion material. The infusion material can pass through the flow guide net and the release cloth and flow to the fiber reinforcement layer to impregnate it. During the impregnation and curing of the fiber reinforcement layer, the infusion material at the flow guide pipe still releases a large amount of heat, which affects the curing of the infusion material in the corresponding area below, resulting in localized whitening of the molded blade component. At the same time, if the injected infusion material contains air bubbles or if air bubbles are generated during the curing process, the air bubbles will accumulate in large numbers, resulting in localized cavities in the molded blade component, affecting the mechanical properties of the blade component.

[0065] The wind turbine blade components formed by the vacuum injection molding method of the present application embodiment are less prone to whitening, and have fewer or no internal air bubbles.

[0066] Figure 2 schematically shows the vacuum casting molding method for wind turbine blade components. Figure 3 schematically shows the vacuum casting molding process for wind turbine blade components. Figure 4 schematically shows a partial structure of the interlayer.

[0067] Referring to Figures 2, 3, and 4, this application provides a vacuum casting molding method for wind turbine blade components, which includes:

[0068] Provide blade mold 10;

[0069] A fiber reinforcement layer 20 is laid on the blade mold 10;

[0070] A release cloth 30 is laid on the fiber reinforcement layer 20;

[0071] Lay a flow guide net 40 on the release fabric 30;

[0072] A partition layer 50 is laid on a local area of ​​the flow guiding net 40. The partition layer 50 includes a heat insulation layer 51 and a bubble dispersion layer 52, and the bubble dispersion layer 52 and the heat insulation layer 51 are connected.

[0073] A guide pipe 60 is provided on the partition 50, and the guide pipe 60 is located on the side of the partition 50 opposite to the guide net 40;

[0074] Lay out 70 mm of vacuum bag film;

[0075] Use a vacuum pump to evacuate air, so that the vacuum bag membrane 70 is under negative pressure;

[0076] An infusion material is provided and injected through a guide tube 60. The infusion material impregnates the fiber reinforcement layer 20 and is then cured to form a blade component.

[0077] In some feasible ways, after the infusion material has been cured and the infusion material and fiber reinforcement layer 20 form a blade component, the release cloth 30, flow guide net 40, partition 50, flow guide tube 60 and vacuum bag film 70 are removed.

[0078] In some feasible embodiments, the temperature of the injection material injected through the guide tube 60 is maintained between 130 and 150 degrees Celsius to ensure good fluidity, thereby enabling good wetting speed and effect. In some examples, the injection material may be a resin material.

[0079] The heat insulation layer 51 in the partition 50 of this embodiment has a heat insulation function, thereby isolating the infusion material at the injection position of the guide tube 60 from the fiber reinforcement layer 20. The heat insulation layer 51 can disperse and block the heat continuously released by the infusion material at the injection position of the guide tube 60, reducing the possibility of heat released by the infusion material at the injection position of the guide tube 60 accumulating in the corresponding area of ​​the fiber reinforcement layer 20.

[0080] In this embodiment, the bubble dispersion layer 52 in the partition 50 has the functions of dispersing and adsorbing bubbles. During the injection stage of the injection material, when the injection material contains bubbles, as the injection material flows through the bubble dispersion layer 52, the bubble dispersion layer 52 can disperse large bubbles into small bubbles and adsorb small bubbles, allowing the small bubbles to remain within the bubble dispersion layer 52, thereby effectively reducing the number of bubbles in the injection material flowing to the fiber reinforcement layer 20. During the curing stage of the injection material, small bubbles in the injection material can continuously aggregate to form large bubbles. The large bubbles can rise and move towards the partition 50. The large bubbles can enter the bubble dispersion layer 52 after passing through the release cloth 30 and the guide net 40. The bubble dispersion layer 52 can disperse large bubbles into small bubbles and adsorb small bubbles, allowing the small bubbles to remain within the bubble dispersion layer 52.

[0081] In the vacuum casting molding method for wind turbine blade components according to this application embodiment, a partition layer 50 is provided on one side of the guide net 40, and a guide pipe 60 is provided on one side of the partition layer 50. The guide pipe 60 is used to introduce a relatively high-temperature casting material. The casting material discharged from the guide pipe 60 releases a large amount of heat. The partition layer 50 can block the casting material discharged from the guide pipe 60. Part of the casting material discharged from the guide pipe 60 can pass through the partition layer 50, the guide net 40, and the release cloth 30 and flow towards the fiber reinforcement layer 20, while part can flow to an area outside the partition layer 50 and pass through the guide net 40 and the release cloth 30 and flow towards the fiber reinforcement layer 20. The partition layer 50 can effectively disperse the casting material discharged from the guide pipe 60, reducing the possibility that the casting material discharged from the guide pipe 60 will continuously release a large amount of heat at the outlet of the guide pipe 60 and form heat accumulation.

[0082] In addition, the heat insulation layer 51 in the partition 50 can effectively isolate the injection material at the guide tube 60 from the fiber reinforcement layer 20 below. During the curing stage of the injection material, the heat released by the injection material at the guide tube 60 is not easily conducted to the fiber reinforcement layer 20, reducing the possibility that the curing rate or curing effect of the injection material below the guide tube 60 may be affected by local high temperature, resulting in local whitening of the molded blade component.

[0083] Furthermore, during the flow of the injection material through the partition layer 50, the bubble dispersion layer 52 within the partition layer 50 can disperse and adsorb the bubbles carried in the injection material, thereby effectively reducing the number of bubbles in the injection material and the number of bubbles in the blade components. Simultaneously, during the curing process of the injection material at the fiber reinforcement layer 20, small bubbles in the injection material can continuously aggregate to form large bubbles. These large bubbles can rise and move towards the partition layer 50. After entering the bubble dispersion layer 52, the large bubbles can be dispersed into smaller bubbles, and the bubble dispersion layer 52 can adsorb the smaller bubbles, causing them to remain within the bubble dispersion layer 52.

[0084] Therefore, the wind turbine blade components formed by the vacuum injection molding method of this application are less prone to localized whitening, and the number of air bubbles inside the blade components is small or non-existent. The wind turbine blade components formed by the vacuum injection molding method of this application have a high yield and good product quality, effectively reducing the possibility of rework, repair, or product scrap.

[0085] In some feasible ways, during the curing process of the infusion material at the fiber reinforcement layer 20, the vacuum bag membrane 70 can be evacuated so that the bubble dispersion layer 52 can be in a negative pressure state, thereby allowing large bubbles formed in the infusion material at the fiber reinforcement layer 20 to rise and move relatively easily to the bubble dispersion layer 52.

[0086] In some feasible ways, the edge of the vacuum bag film 70 can be bonded to the blade mold 10 using tape or adhesive to form a sealed space under the vacuum bag film 70.

[0087] In some feasible implementations, Figure 5 schematically shows a partial structure in the vacuum infusion molding process of wind turbine blade components. Referring to Figure 5, a porous separator 80 is laid on the release fabric 30. Then, a flow guide net 40 is laid on the porous separator 80. The porous separator 80 has a porous structure, which facilitates the smooth penetration of the infusion material. The porous separator 80 can separate the release fabric 30 and the flow guide net 40. The flow guide net 40 can be used to disperse the infusion material. The porous separator 80 can be used to further disperse the infusion material that has passed through the flow guide net 40, so that the infusion material can uniformly penetrate and wet the fiber reinforcement layer 20.

[0088] In some feasible embodiments, as shown in Figure 4, a heat insulation layer 51 is provided on one side of the bubble dispersion layer 52. While meeting the heat insulation performance requirements, the thickness of the spacer 50 itself can be relatively small, which helps to reduce the flow resistance to the injection material.

[0089] In some examples, the bubble dispersion layer 52 is provided with an insulation layer 51 on the side facing the flow guide net 40. The bubble dispersion layer 52 is located close to the flow guide pipe 60. Alternatively, the bubble dispersion layer 52 is provided with an insulation layer 51 on the side facing away from the flow guide net 40. The insulation layer 51 is located close to the flow guide pipe 60.

[0090] In some feasible implementations, Figure 6 schematically shows a partial structure of the insulating layer 50. Referring to Figure 6, heat insulation layers 51 are respectively disposed on opposite sides of the bubble dispersion layer 52. The heat insulation layer 51, the bubble dispersion layer 52, and the heat insulation layer 51 are stacked sequentially. By distributing heat insulation layers 51 on opposite sides of the bubble dispersion layer 52, a greater number of heat insulation layers 51 can effectively isolate the infusion material and the fiber reinforcement layer 20, further reducing heat conduction. In some examples, the number of heat insulation layers 51 is two. The bubble dispersion layer 52 is disposed between the two heat insulation layers 51.

[0091] In some implementations, the bubble dispersion layer 52 and the insulation layer 51 are bonded together. An adhesive is applied to the surface of the insulation layer 51, and then the bubble dispersion layer 52 is bonded to the insulation layer 51. The bonded bubble dispersion layer 52 and insulation layer 51 form a spacer 50. In some examples, where not laid to the blade mold 10, both the insulation layer 51 and the bubble dispersion layer 52 are rectangular. Adhesive is applied at 0.25 m intervals along the length of the insulation layer 51 on each of its two long edges. The bubble dispersion layer 52 is then bonded to the insulation layer 51. The two long edges of the insulation layer 51 are bonded to the two long edges of the bubble dispersion layer 52, respectively, so that most areas outside the bonding area do not affect the permeation of the infusion material. Exemplarily, the adhesive can be a hot melt adhesive. In some examples, the material of the insulation layer 51 can be, but is not limited to, fiberglass or polypropylene (PP). The material of the bubble dispersion layer 52 can be, but is not limited to, polyethylene (PE) or polypropylene (PP).

[0092] In some feasible embodiments, the bubble dispersion layer 52 and the heat insulation layer 51 are integrally formed. The connection between the bubble dispersion layer 52 and the heat insulation layer 51 is stable and not easily separated. In some examples, the spacer 50 is manufactured using a one-piece injection molding process or a 3D printing process. In some examples, the material of the heat insulation layer 51 can be the same as the material of the bubble dispersion layer 52.

[0093] In some feasible implementations, Figure 7 schematically shows a partial structure of the connection between the partition 50 and the guide tube 60. Figure 8 schematically shows a partial structure in the vacuum infusion molding process of wind turbine blade components. Referring to Figures 7 and 8, along the thickness direction Z of the partition 50, the orthographic projection of the guide tube 60 lies within the orthographic projection of the partition 50. The infusion material at the guide tube 60 can be completely blocked by the partition 50, further effectively improving the insulation effect of the partition 50 on the heat released by the infusion material at the guide tube 60. The infusion material discharged from the guide tube 60 cannot flow directly to the guide net 40. Part of the infusion material discharged from the guide tube 60 can flow directly through the partition 50 to the guide net 40, and part can flow from the partition 50 to an area without the partition 50 and then to the guide net 40. The partition 50 can effectively disperse the infusion material discharged from the guide tube 60, which is beneficial to improving the infusion efficiency.

[0094] In some examples, two or more partitions 50 and two or more guide tubes 60 are spaced apart along the length of the blade mold 10. Exemplarily, the number of partitions 50 and the number of guide tubes 60 can be set in a one-to-one correspondence.

[0095] In some examples, the partition 50 extends beyond the guide tube 60 by a dimension greater than or equal to 1 mm. When the partition 50 extends beyond the guide tube 60 by less than 1 mm, the dispersion effect of the partition 50 on the injection material is not significant.

[0096] In some examples, the dimension of the partition 50 extending beyond the guide tube 60 is less than or equal to 10 mm. When the dimension of the partition 50 extending beyond the guide tube 60 is greater than 10 mm, the area of ​​the partition 50 itself is relatively large, causing most of the injection material to need to penetrate downward through the partition 50, resulting in lower injection efficiency and affecting the injection effect.

[0097] In some feasible methods, a partition layer 50 is provided in areas where the number of fiber reinforcement layers 20 is greater than or equal to 40. The overall thickness of these areas is relatively large, resulting in a relatively large amount of infusion material impregnation. Consequently, the infusion material in these areas is more susceptible to external heat during curing. Therefore, providing a partition layer 50 in areas where the number of fiber reinforcement layers 20 is greater than or equal to 40 can effectively reduce the downward conduction of heat released from the infusion material at the guide tube 60, thus reducing the possibility of localized whitening caused by external heat affecting the curing process of the infusion material.

[0098] In some feasible embodiments, Figure 9 schematically shows a partial structure in the vacuum infusion molding process of wind turbine blade components. Referring to Figure 9, a fiber reinforcement layer 20 is laid on the blade mold 10, then a core material 90 is laid on the fiber reinforcement layer 20, and finally, another fiber reinforcement layer 20 is laid on the core material 90. A spacer layer 50 is provided corresponding to the core material 90.

[0099] In the area where the core material 90 is located, the overall thickness formed by the fiber reinforcement layer 20 and the core material 90 is relatively large, resulting in a relatively large amount of infusion material impregnation. Consequently, the infusion material in this area is relatively susceptible to external heat during the curing process. Therefore, by placing a partition layer 50 above the core material 90, the heat released by the infusion material at the guide tube 60 can be effectively reduced to conduct downwards, which helps to reduce the possibility of localized whitening caused by external heat affecting the curing process of the infusion material.

[0100] In some examples, the core material 90 has a thickness of 35 mm or more, and the corresponding area is provided with a partition 50.

[0101] In some examples, the core material 90 can be a balsa wood core, such as balsa wood. During the process of impregnating the core material 90 with a high-temperature infusion material, the moisture overflowing from the core material 90 will generate air bubbles in the infusion material. The spacer 50 is configured in a manner corresponding to the core material 90, so that the air bubbles generated in the infusion material can move to the bubble dispersion layer 52 and be dispersed and adsorbed by the bubble dispersion layer 52.

[0102] In some examples, the core material 90 can be a foam core material.

[0103] In some feasible ways, the guide tube 60 and the partition 50 are connected by at least one of adhesive bonding and wire bonding.

[0104] In some examples, the flow guide tube 60 and the partition 50 are connected by adhesive. Adhesive can be applied to the partition 50, and then the flow guide tube 60 is bonded to it. This adhesive bonding method eliminates the need for additional connection structures or connectors for either the partition 50 or the flow guide tube 60, reducing the manufacturing complexity of both and minimizing the number of components required.

[0105] In some examples, the guide tube 60 is connected to the partition 50 using a wire bonding method. After the guide tube 60 is placed on the partition 50, wire is wrapped around the partition 50 and the guide tube 60 to secure them. Using a wire bonding method to connect the guide tube 60 and the partition 50 improves the stability and reliability of the connection between the partition 50 and the guide tube 60, and reduces the possibility of separation due to external forces.

[0106] In some examples, the flow guide tube 60 and the partition 50 are connected by adhesive bonding and wire binding. After the partition 50 and the flow guide tube 60 are bonded together, wire is then wrapped around the partition 50 and the flow guide tube 60 to secure them.

[0107] In some examples, the cross-section of the guide tube 60 can be semi-circular or V-shaped. A cavity is formed between the guide tube 60 and the partition 50. A filling pipe can be connected to the middle position of the guide tube 60 along its axial direction. The filling pipe is used to deliver the filling material.

[0108] In some feasible implementations, the partition 50 and the guide tube 60 are integrally formed. The connection between the partition 50 and the guide tube 60 is stable and not easily separated. In some examples, the partition 50 and the guide tube 60 are manufactured using a one-piece injection molding process or a 3D printing process. In some examples, the materials of the insulation layer 51 and the guide tube 60 can be the same.

[0109] In some possible implementations, Figure 10 schematically shows a partial structure of the flow guide 60. Referring to Figures 7 and 10, the flow guide 60 includes a first outlet 61 and a second outlet 62. The first outlet 61 is disposed facing the partition 50. The second outlets 62 are respectively disposed on two opposite end faces along the axial direction of the flow guide 60. The axial direction of the flow guide 60 may be perpendicular to the thickness direction Z of the partition 50. The flow guide 60 may include one first outlet 61 and two second outlets 62.

[0110] Both the first outlet 61 and the second outlet 62 of the guide tube 60 are used to discharge the injection material. The injection material discharged from the first outlet 61 of the guide tube 60 can directly pass through the partition 50 and wet the fiber reinforcement layer 20 below. The injection material discharged from the second outlet 62 of the guide tube 60 can first flow to the partition 50, and then flow from the partition 50 to the area without the partition 50, and then wet the fiber reinforcement layer 20 below. The guide tube 60 and the partition 50 work together to effectively disperse the injection material, which helps to improve the injection efficiency.

[0111] In some feasible implementations, Figure 11 schematically shows a partial structure of the interlayer 50. Referring to Figure 11, the bubble dispersion layer 52 comprises a first fiber layer woven from warp and weft yarns. The insulating layer 51 is connected to the first fiber layer. The bubble dispersion layer 52 is a woven structure. The bubble dispersion layer 52, formed by the weaving process, ensures smooth penetration of the infusion material and effective dispersion and adsorption of bubbles. In some examples, both the warp and weft yarns can be fiber filaments or plastic threads. In some examples, the bubble dispersion layer 52 includes a first fiber layer.

[0112] In some feasible implementations, Figure 12 schematically shows a partial structure of the interlayer 50. Referring to Figure 12, the bubble dispersion layer 52 includes a first fiber layer 521 and a second fiber layer 522. The first fiber layer 521 is woven from warp and weft threads. The second fiber layer 522 is disposed between the two first fiber layers 521. The second fiber layer 522 supports the first fiber layers 521. The thermal insulation layer 51 is connected to the first fiber layers 521. The bubble dispersion layer 52 can have more pores, which is beneficial for improving the dispersion ability of the infusion material and the bubble dispersion ability. The bubble dispersion layer 52 can have a larger surface area, which is beneficial for improving the adsorption capacity for small bubbles.

[0113] In some examples, the second fiber layer 522 comprises randomly arranged fiber filaments. These randomly arranged fiber filaments fill the space between the two first fiber layers 521. Irregular channels are formed in the second fiber layer 522, allowing the second fiber layer 522 to permeate with an infusion material.

[0114] In some examples, the first fiber layer 521 and the second fiber layer 522 are bonded together. Alternatively, the first fiber layer 521 and the second fiber layer 522 are integrally formed. Exemplarily, a bubble dispersion layer 52 comprising the first fiber layer 521 and the second fiber layer 522 can be manufactured using a 3D printing process.

[0115] In some feasible implementations, Figure 13 schematically shows a partial structure of the insulation layer 51. Referring to Figure 13, the insulation layer 51 includes a first through-hole 51a. The first through-hole 51a penetrates the insulation layer 51 along the thickness direction Z of the interlayer 50. The first through-hole 51a of the insulation layer 51 ensures that the injection material can smoothly permeate through the insulation layer 51, reducing the flow resistance generated by the insulation layer 51 on the injection material, thereby ensuring good injection efficiency of the injection material.

[0116] In some examples, the insulation layer 51 includes two or more first through holes 51a. The two or more first through holes 51a may be distributed in an array.

[0117] In some examples, the cross-sectional area of ​​the first through hole 51a is S1. The projected area of ​​the insulation layer 51 along the thickness direction Z of the interlayer 50 is S2. The value of S1 / S2 ranges from 0.000049 to 0.008, which ensures that the insulation layer 51 has good permeability of the injection material and also ensures that the insulation layer 51 has good heat insulation performance.

[0118] For example, the heat insulation layer 51 is rectangular in shape. The axial direction of the guide tube 60 is the same as the length direction of the heat insulation layer 51. The first through hole 51a is a rectangular hole, for example, a rectangular hole.

[0119] For example, the length of the insulation layer 51 can range from 1 meter (m) to 4 meters. The width of the insulation layer 51 can be 100 millimeters (mm). The thickness of the insulation layer 51 can range from 3 millimeters to 10 millimeters. The length of the first through hole 51a can be 80 millimeters. The width of the first through hole 51a can be 10 millimeters. The length direction of the first through hole 51a is the same as the width direction of the insulation layer 51. Two or more first through holes 51a are spaced apart along the length direction of the insulation layer 51. The hole spacing between two adjacent first through holes 51a is 20 millimeters. The distance from the first through hole 51a to the edge of the insulation layer 51 can be 10 millimeters.

[0120] For example, FIG14 schematically shows a partial structure of the insulation layer 51. Referring to FIG14, the insulation layer 51 is rectangular in shape. For example, the insulation layer 51 is rectangular in shape. The first through hole 51a is a circular hole.

[0121] For example, the length of the insulation layer 51 can range from 1 meter (m) to 4 meters. The width of the insulation layer 51 can be 100 millimeters (mm). The thickness of the insulation layer 51 can range from 3 millimeters to 10 millimeters. The diameter of the first through hole 51a can range from 5 millimeters to 10 millimeters. Two or more first through holes 51a are spaced apart. The spacing between two adjacent first through holes 51a is 10 millimeters. The dimension between the first through hole 51a closest to the edge of the insulation layer 51 and the edge of the insulation layer 51 can be 10 millimeters.

[0122] In some feasible implementations, Figure 15 schematically shows a partial structure of the bubble dispersion layer 52. Referring to Figure 15, the bubble dispersion layer 52 includes a second through-hole 52a. The second through-hole 52a extends through the bubble dispersion layer 52 along the thickness direction Z of the separator 50. The first through-hole 51a of the insulation layer 51 communicates with the second through-hole 52a of the bubble dispersion layer 52. The second through-hole 52a of the bubble dispersion layer 52 ensures that the injection material can smoothly penetrate through the bubble dispersion layer 52, reducing the flow resistance generated by the bubble dispersion layer 52 on the injection material, thereby ensuring good injection efficiency. Simultaneously, during the injection stage, the second through-hole 52a of the bubble dispersion layer 52 can be used to disperse large bubbles, breaking them down into smaller bubbles.

[0123] In some examples, the cross-sectional area of ​​the second through hole 52a is S11. Along the thickness direction Z of the interlayer 50, the projected area of ​​the bubble dispersion layer 52 is S22. The value of S11 / S22 ranges from 0.00000785 to 0.00003, thus ensuring that the bubble dispersion layer 52 has good permeability to the injection material and also good dispersion ability.

[0124] In some examples, the bubble dispersion layer 52 is rectangular in shape. For example, the bubble dispersion layer 52 is rectangular in shape. There are two or more second through holes 52a. At least two second through holes 52a are interconnected, which helps to improve the permeability of the injection material in the bubble dispersion layer 52. Exemplarily, the shape of the bubble dispersion layer 52 can be the same as the shape of the insulation layer 51. Along the thickness direction Z of the interlayer 50, the orthographic projection outer contour of the bubble dispersion layer 52 coincides with the orthographic projection outer contour of the insulation layer 51.

[0125] For example, the length of the bubble dispersion layer 52 can range from 1 meter (m) to 4 meters. The width of the bubble dispersion layer 52 can be 100 millimeters (mm). The thickness of the bubble dispersion layer 52 can range from 1 millimeter to 10 millimeters.

[0126] For example, the cross-section of the second through hole 52a is circular. The diameter of the second through hole 52a is 2 mm. Two or more second through holes 52a are spaced apart. The distance between two adjacent second through holes 52a ranges from 2 mm to 10 mm.

[0127] In some feasible methods, the thickness of the insulation layer 51 ranges from 3 mm to 10 mm. When the thickness of the insulation layer 51 is less than 3 mm, its structural strength is relatively low, making it prone to breakage and failure under tensile forces. When the thickness of the insulation layer 51 is greater than 10 mm, its resistance to the flow of the injection material increases, affecting the injection efficiency. Therefore, a thickness range of 3 mm to 10 mm for the insulation layer 51 effectively solves the above problems.

[0128] In some feasible ways, the thickness of the bubble dispersion layer 52 ranges from 1 mm to 10 mm.

[0129] When the thickness of the bubble dispersion layer 52 is less than 1 mm, its structural strength is relatively low, making it prone to breakage and failure under tensile forces. When the thickness of the bubble dispersion layer 52 is greater than 10 mm, its resistance to the flow of the injection material increases, affecting the injection efficiency. Therefore, a thickness of 1 mm to 10 mm for the bubble dispersion layer 52 effectively solves these problems.

[0130] Although this application has been described with reference to preferred embodiments, various modifications can be made thereto and components can be replaced with equivalents without departing from the scope of this application. In particular, the technical features mentioned in the various embodiments can be combined in any manner, provided there is no structural conflict. This application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A method for vacuum infusion forming a wind turbine blade component, comprising: providing a blade mold; laying a fiber reinforced layer on the blade mold; laying a release cloth on the fiber reinforced layer; laying a flow guide net on the release cloth; laying a spacer layer on a partial area of the flow guide net, the spacer layer comprising a bubble dispersion layer and a thermal insulation layer, the bubble dispersion layer and the thermal insulation layer being connected; arranging a flow guide tube on the spacer layer, the flow guide tube being located on a side of the spacer layer facing away from the flow guide net; laying a vacuum bag film; using a vacuum pump to draw air, so that the vacuum bag film is under negative pressure; providing an infusion material, the infusion material being injected through the flow guide tube, the infusion material infiltrating the fiber reinforced layer and being subjected to a curing process to form a blade component. One side of the bubble dispersion layer is provided with the thermal insulation layer; or, opposite sides of the bubble dispersion layer are respectively provided with the thermal insulation layer. The bubble dispersion layer and the thermal insulation layer are bonded; or, the bubble dispersion layer and the thermal insulation layer are integrally formed. An orthographic projection of the flow guide tube along a thickness direction of the spacer layer is located within an orthographic projection of the spacer layer. A size of the spacer layer exceeding the flow guide tube is greater than or equal to 1 mm. The spacer layer is correspondingly arranged in an area where a number of layers of the fiber reinforced layer is greater than or equal to 40 layers; and / or, the fiber reinforced layer is laid on the blade mold, a core material is laid on the fiber reinforced layer, the fiber reinforced layer is laid on the core material, and the spacer layer is correspondingly arranged for the core material. The flow guide tube and the spacer layer are connected in at least one of a bonding mode and a wire binding mode; or, the spacer layer and the flow guide tube are integrally formed. The bubble dispersion layer comprises a first fiber layer woven by warp and weft threads; or, the bubble dispersion layer comprises a first fiber layer woven by warp and weft threads and a second fiber layer, the second fiber layer is arranged between two first fiber layers, and the second fiber layer supports the first fiber layer; the thermal insulation layer is connected with the first fiber layer. The flow guide tube comprises a first liquid outlet and a second liquid outlet, the first liquid outlet faces the spacer layer, and the second liquid outlet is arranged on each of two end faces of the flow guide tube in an axial direction of the flow guide tube. The thermal insulation layer comprises a first through hole, the first through hole penetrates the thermal insulation layer along a thickness direction of the spacer layer. A cross-sectional area of the first through hole is S1, and an orthographic projection area of the thermal insulation layer along the thickness direction of the spacer layer is S2, wherein a value range of S1 / S2 is 0.000049 to 0.

008. The thermal insulation layer has a rectangular shape, and the first through hole is a rectangular hole or a circular hole. The bubble dispersion layer comprises a second through hole, the second through hole penetrates the bubble dispersion layer along the thickness direction of the spacer layer. A cross-sectional area of the second through hole is S11, and an orthographic projection area of the bubble dispersion layer along the thickness direction of the spacer layer is S22, wherein a value range of S11 / S22 is 0.00000785 to 0.00003. ​ ​ ​ ​ ​ ​ ​ ​ ​ 2. A wind turbine blade component vacuum infusion moulding method according to claim 1, wherein, ​ 3. A wind turbine blade component vacuum infusion moulding method according to claim 1, wherein, ​ 4. A wind turbine blade component vacuum infusion moulding method according to claim 1, wherein, ​ 5. A wind turbine blade component vacuum infusion moulding method according to claim 4, wherein, ​ 6. A wind turbine blade component vacuum infusion moulding method according to claim 1, wherein, ​ ​ ​ 7. A wind turbine blade component vacuum infusion moulding method according to claim 1, wherein, ​ 8. A wind turbine blade component vacuum infusion moulding method according to claim 1, wherein, ​ ​ 9. A wind turbine blade component vacuum infusion moulding method according to claim 1, wherein, ​ 10. A vacuum infusion process for wind turbine blade members according to claim 1, wherein, ​ 11. A wind turbine blade component vacuum infusion moulding method according to claim 10, wherein, ​ 12. A wind turbine blade component vacuum infusion moulding method according to claim 10 or 11, wherein, ​ 13. A wind turbine blade component vacuum infusion moulding method according to claim 1, wherein, ​ 14. A wind turbine blade component vacuum infusion moulding method according to claim 13, wherein, ​ 15. A wind turbine blade component vacuum infusion moulding method according to claim 13 or 14, wherein, The shape of the bubble dispersion layer is rectangular, the number of the second through holes is two or more, and at least two of the second through holes are in communication with each other.

16. A wind turbine blade component vacuum infusion moulding method according to claim 1, wherein, The thickness of the heat insulation layer is in the range of 3-10 mm, and / or the thickness of the bubble dispersion layer is in the range of 1-10 mm.

17. A wind turbine blade component vacuum infusion moulding method according to claim 1, wherein, A porous release film is laid on the release cloth, and a drainage net is laid on the porous release film.

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