Modular thermoplastic web structure for wind power, manufacturing method therefor and wind turbine blade

Abstract

A modular thermoplastic web structure for wind power, a manufacturing method therefor and a wind turbine blade. The modular thermoplastic web structure comprises: two continuous thermoset web flanges (11) fixedly connected to a wind turbine blade shell, and a thermoplastic modular interlayer (10). The thermoplastic modular interlayer (10) is arranged between the two continuous thermoset web flanges (11), with ends thereof being fixedly connected to the continuous thermoset web flanges (11).

Description

Modular thermoplastic web structure for wind power, manufacturing method and wind power blade Cross-reference to related applications

[0001] This application is based on and claims priority to Chinese patent application No. 202411108287.X, filed on August 13, 2024, the entire contents of which are incorporated herein by reference. TECHNICAL FIELD

[0002] The present application belongs to the technical field of wind turbines, and specifically, the present application relates to a modular thermoplastic web structure for wind power, a manufacturing method and a wind power blade. BACKGROUND

[0003] Currently, wind power blades use traditional thermosetting resin and vacuum infusion process to prepare the web, which takes a long time to produce and is prone to infusion defects such as web micro-cracks and poor infiltration. As blades become larger, the web mold also needs to be correspondingly increased and expanded, resulting in increased investment costs. At the same time, thermoset webs cannot be recycled and reused, and the production of all-thermoplastic webs has problems such as difficulty in preparation and poor interface performance.

[0004] For example, the manufacturing method of the web for the fan blade disclosed in CN202110474817.2 uses fiber-reinforced composite materials to manufacture multiple web modules, the web module includes a flat plate body and multiple reinforcing members, and the multiple reinforcing members are connected with the flat plate body; and the multiple web modules are connected together to form the web for the fan blade. As disclosed in patent CN115807731A, a wind power blade web and a forming method thereof use pultrusion components and core materials for co-infusion, which cannot control infusion defects. In addition, as disclosed in CN107923365A, the shear-resistant web uses discrete springs to fix the panel. The above-mentioned patents all use thermosetting materials, and the web cannot be recycled. Although patents US11035339B2 and US10697425B2 use thermoplastic web designs, they cannot effectively solve the interface performance problem and are difficult to utilize quickly. SUMMARY

[0005] The purpose of the present application is to provide a modular thermoplastic web structure for wind power, a manufacturing method and a wind power blade.

[0006] In a first aspect, the present application provides a modular thermoplastic web structure for wind power, comprising: a continuous thermoset web flange fixedly connected to a wind blade shell; and a thermoplastic modular interlayer, the thermoplastic modular interlayer is arranged between two continuous thermoset web flanges, and the end is fixedly connected with the continuous thermoset web flange.

[0007] In a second aspect, the application further provides a method for manufacturing the modular thermoplastic web structure, comprising the following steps: (1) first preparing a thermoplastic skin layer using a thermoplastic prepreg tape, then compounding the thermoplastic skin layer with a core material layer to obtain a thermoplastic modular sandwich, and cutting to a suitable size; (2) preparing a continuous thermoset web flange using a thermoset resin and dry reinforcing fibers; (3) fixing the thermoplastic modular sandwich after surface pretreatment with the continuous thermoset web flange; or comprising the following steps: (A) first preparing a thermoplastic skin layer using a thermoplastic prepreg tape, then compounding the thermoplastic skin layer with a core material layer to obtain a thermoplastic modular sandwich, and cutting to a suitable size; (B) after surface pretreatment of the thermoplastic modular sandwich, laying dry reinforcing fibers in the web flange mold and the thermoplastic modular sandwich area, and then pouring and curing to form; or comprising the following steps: (I) first preparing a thermoplastic skin layer using a thermoplastic prepreg tape, then compounding the thermoplastic skin layer with a core material layer to obtain a thermoplastic modular sandwich, and cutting to a suitable size; (II) after surface pretreatment of the thermoplastic modular sandwich, laying dry reinforcing fibers in the installation position of the wind turbine blade shell and the thermoplastic modular sandwich area, and then pouring and curing to form.

[0008] In a third aspect, the application further provides a wind power generation blade, comprising a wind turbine blade shell and the modular thermoplastic web structure for wind power generation as provided in the first aspect above.

[0009] The modular thermoplastic web structure for wind power generation provided by the application can realize stable production of the web of the wind power generation blade, reduce the cost of the production piece, while ensuring stable product quality and performance, and reducing potential pouring defects and CoPQ (cost of poor quality) and the like. BRIEF DESCRIPTION OF DRAWINGS

[0010] Fig. 1 is a front view schematic diagram of the modular thermoplastic web structure and the wind power generation blade during installation;

[0011] Fig. 2 is a side view schematic diagram of the modular thermoplastic web structure and the wind power generation blade during installation;

[0012] Fig. 3 is a schematic diagram of the preparation of the thermoplastic modular sandwich;

[0013] Fig. 4 is a schematic diagram of the surface pretreatment of the thermoplastic modular sandwich;

[0014] Fig. 5 is a schematic diagram of the assembly of the continuous thermoset web flange and the thermoplastic modular sandwich in a prefabricated form;

[0015] Fig. 6 is a schematic diagram of the assembly of the continuous thermoset web flange and the thermoplastic modular sandwich using co-pouring;

[0016] Fig. 7 is a schematic diagram of the assembly of the continuous thermoset web flange, the wind turbine blade shell and the thermoplastic modular sandwich using co-pouring;

[0017] Legend in the figure:

[0018] 10 - thermoplastic modular sandwich, 11 - continuous thermoset web flange, 12 - first interlayer;

[0019] 21 - thermoplastic prepreg tape, 22 - thermoplastic skin layer, 23 - core material layer, 24 - second interlayer;

[0020] 31 - third interlayer;

[0021] 40 - flange mold. DETAILED DESCRIPTION

[0022] The application will be described in detail below with reference to the drawings and specific embodiments. The embodiments are implemented on the premise of the technical solutions of the application, and detailed implementation methods and specific operation processes are given, but the protection scope of the application is not limited to the following embodiments.

[0023] In the description of the present application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. In addition, the terms "first", "second", "third" are only for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0024] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mounting", "connecting", "connecting" should be understood in a broad sense, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0025] In the following embodiments or examples, if there is no special description of the function parts or structures, it means that they are all conventional parts or conventional structures adopted by the field to realize the corresponding functions; if there is no special description of the processing or preparation technology, it means that it is a conventional technology in the field.

[0026] To realize stable production and effective recovery of the wind power blade web, the application provides a modular thermoplastic web structure for wind power, which comprises: continuous thermoset web flanges 11 fixedly connected with a wind blade shell; and a thermoplastic modular sandwich 10 arranged between the two continuous thermoset web flanges 11 and fixedly connected with the continuous thermoset web flanges 11 at the ends.

[0027] In the specific assembly, as shown in FIGS. 1-3, the continuous thermoset web flanges 11 can be connected with the blade shell by forming a first intermediate layer 12 through a conventional structural glue or resin pouring, etc.

[0028] In some embodiments, the thermoplastic modular sandwich 10 comprises a core layer 23 in the middle and thermoplastic skin layers 22 covering the opposite two sides of the core layer 23. As shown in FIG. 3, the thermoplastic skin layers 22 are arranged on the two sides of the core layer 23, and can be connected with the core layer 23 in the manner of the second intermediate layer 24, which can be one or more of a glue film, a resin film or a thermoplastic prepreg tape.

[0029] In some embodiments, the thermoplastic skin layer 22 here can be a multi-layer fiber tape layer, which can preferably be made of a thermoplastic prepreg tape 21 or a thermoplastic resin powder and dry fibers according to different layup structures. Specifically, the + / -45° layup method can be used to prepare the thermoplastic skin layer 22 by continuous molding. The continuous molding here includes the forming process of a belt machine, a steel belt machine or a continuous molding machine.

[0030] In some embodiments, the thickness of the thermoplastic skin layer 22 is 1-10 mm, and the thermoplastic resin powder used can be one of polyimide, polyamide nylon, polycarbonate, polyether ketone, polyether ether ketone, polyether ketone ketone, polypropylene, polyethylene, polysulfone, polyvinyl chloride, polyurethane, polyacetal, polyether nitrile, polymethacrylate, polyphenylene sulfide, polylactic acid, polystyrene.

[0031] In some embodiments, the thermoplastic prepreg tape 21 is one or more of a unidirectional prepreg tape, a fabric prepreg tape, a twill prepreg tape, a biaxial or multi-axial prepreg tape, with a thickness of 0.1-2 mm and a fiber mass fraction of 40-95%. Here, the continuous fibers used in the thermoplastic prepreg tape 21 can be one or more of glass fiber, ceramic fiber, metal fiber, carbon fiber, basalt fiber, regenerated fiber or synthetic fiber.

[0032] In some embodiments, the thickness of the core layer 23 is 5-100 mm, and the core material used can be one or more of basswood, PET, PA, PVC, PU, PP and PC.

[0033] In some embodiments, the thermoplastic skin layer 22 and the core material layer 23 are fixedly connected by welding, gluing or film.

[0034] In some embodiments, the thermoplastic modular sandwich 10 comprises a plurality of unit modules, wherein the number of unit modules in the same position chord direction is not more than 5, and the adjacent two unit modules are connected by gluing or welding, and the thermoplastic skin layer 22 is used for reinforcing connection.

[0035] In some embodiments, the cross section of the continuous thermoset web flange 11 is in the shape of "π", the web flange angle is 60°-150°, the web flange width is 50-250mm, and the profile of the wind turbine blade shell is kept in shape. When connected with the thermoplastic modular sandwich 10, the opening area in the shape of "π" can be connected and fixed by wrapping the thermoplastic modular sandwich 10 on three sides.

[0036] In some embodiments, the "π" shaped opening width of the continuous thermoset web flange 11 exceeds the thermoplastic modular sandwich 0-10mm.

[0037] In some embodiments, the continuous thermoset web flange 11 is formed by pouring or pultrusion of thermosetting resin and dry reinforcing fibers.

[0038] In some embodiments, the thermosetting resin is one of epoxy resin, polyurethane resin, unsaturated polyester and vinyl resin.

[0039] In some embodiments, the dry reinforcing fibers are one or more of glass fibers, ceramic fibers, metal fibers, carbon fibers, basalt fibers, regenerated fibers or synthetic fibers.

[0040] In some embodiments, the continuous thermoset web flange 11 is continuous in the axial direction, or is segmented according to the design structure of the wind turbine blade, and the number of segments is not more than 3. When the continuous thermoset web flange 11 is segmented, the production of each segment is continuous.

[0041] In some embodiments, the thermoplastic modular sandwich 10 and the continuous thermoset web flange 11 can be connected by resin connection or structural adhesive connection to form a third intermediate layer 31 to realize fixed connection. In particular, when using resin connection, dry reinforcing fibers are laid on three sides of the thermoplastic modular sandwich 10, and then vacuum pouring or other methods are used for curing and forming (to obtain the continuous thermoset web flange 11), and the connection with the blade shell is realized.

[0042] In some embodiments, as shown in Figure 4, the thermoplastic modular sandwich 10 also undergoes surface pretreatment, which can activate the thermoplastic surface, thereby enhancing the interface performance and improving the connection stability effect between the continuous thermoset web flange 11 and the thermoplastic modular sandwich 10.

[0043] In some embodiments, the surface pretreatment can employ one or more of plasma, ultraviolet light irradiation, electron beam, sandblasting, and gamma ray irradiation.

[0044] The application also provides a method for manufacturing a modular thermoplastic web structure. Depending on the connection mode between the continuous thermoset web flange 11 and the thermoplastic modular sandwich 10, there can be at least two forming modes as follows:

[0045] The first forming mode adopts the continuous thermoset web flange 11 prefabrication mode, which can specifically include the following steps: (1) first, a thermoplastic skin layer 22 is prepared using a thermoplastic prepreg tape 21, and then the thermoplastic skin layer 22 is combined with a core material layer 23 to obtain a thermoplastic modular sandwich 10, which is then cut to the appropriate size; (2) the continuous thermoset web flange 11 is prepared using a thermoset resin and dry reinforcing fibers; and (3) after surface pretreatment of the thermoplastic modular sandwich 10, the thermoplastic modular sandwich 10 is fixed with the continuous thermoset web flange 11.

[0046] The second forming mode adopts the continuous thermoset web flange 11 and the thermoplastic modular sandwich 10 co-injection, or the continuous thermoset web flange 11, the thermoplastic modular sandwich 10, and the blade shell co-injection mode, which can specifically include the following steps: (A) first, a thermoplastic skin layer is prepared using a thermoplastic prepreg tape, and then the thermoplastic skin layer is combined with a core material layer to obtain a thermoplastic modular sandwich, which is then cut to the appropriate size; (B) after surface pretreatment of the thermoplastic modular sandwich, dry reinforcing fibers are laid in the web flange mold and the thermoplastic modular sandwich area, and then injection and curing are performed.

[0047] or including the following steps: (I) first, a thermoplastic skin layer is prepared using a thermoplastic prepreg tape, and then the thermoplastic skin layer is combined with a core material layer to obtain a thermoplastic modular sandwich, which is then cut to the appropriate size; (II) after surface pretreatment of the thermoplastic modular sandwich, dry reinforcing fibers are laid in the installation position of the wind blade shell and the thermoplastic modular sandwich area, and then injection and curing are performed.

[0048] Each of the above embodiments can be implemented individually, or in any combination of two or more. The above embodiments will be described in more detail below in conjunction with specific examples.

[0049] Comparative Example 1: Thermoset web production.

[0050] 1) Dry fibers and dry sandwich were used to lay on the web mold, and a thermoset web was prepared using a vacuum injection process, using epoxy 180 / 185 resin, biaxial 800 fibers, and PET foam, with a curing temperature of 70°C.

[0051] The hot set - hot set (i.e. interface between hot set web flange and hot set sandwich) interfacial tensile shear performance was tested to be 35.3 MPa.

[0052] Comparative Example 2: Continuous hot set web flange 11 was bonded with thermoplastic modular sandwich 10.

[0053] 1) Thermoplastic prepreg tape 21 of nylon material was used to make thermoplastic skin ply 22 by + / - 45° layup and then continuous molding.

[0054] 2) Thermoplastic skin ply 22, nylon film (i.e. second intermediate layer 24) and PET foam (i.e. core material layer 23) were used to make thermoplastic modular sandwich 10 by continuous molding.

[0055] 3) As shown in FIG. 5, thermoplastic modular sandwich 10 was placed on a platform, continuous hot set web flange 11 was placed on both sides, vacuum bag was used for fixation, epoxy adhesive was used for bonding and curing to form third intermediate layer 31, thereby obtaining modular thermoplastic web.

[0056] The hot set - thermoplastic interfacial tensile shear performance without surface pretreatment was tested to be 12.9 MPa.

[0057] Comparative Example 3: Continuous hot set web flange 11 was co-infused with thermoplastic modular sandwich 10.

[0058] 1) Thermoplastic prepreg tape 21 of nylon material was used to make thermoplastic skin ply 22 by + / - 45° layup and then continuous molding.

[0059] 2) Thermoplastic skin ply 22, nylon film (i.e. second intermediate layer 24) and PET foam (i.e. core material layer 23) were used to make thermoplastic modular sandwich 10 by continuous molding.

[0060] 3) As shown in FIG. 6, small web flange mold (i.e. flange mold 40) was used to lay biaxial 800 fiber on both sides of thermoplastic skin ply 22, vacuum infusion process was used, epoxy 180 / 185 resin was used, curing temperature was 70°C, hot set web flange 11 was prepared, and thermoplastic modular sandwich 10 was simultaneously consolidated to form modular thermoplastic web.

[0061] The hot set - thermoplastic interfacial tensile shear performance without surface pretreatment was tested to be 15.2 MPa.

[0062] Example 1: Continuous hot set web flange 11 was pre-prepared.

[0063] 1) Thermoplastic prepreg tape 21 of nylon material was used to make thermoplastic skin ply 22 by + / - 45° layup and then continuous molding.

[0064] 2) Thermoplastic skin layer 22, nylon film (i.e. second intermediate layer 24) and PET foam (i.e. core layer 23) were prepared into thermoplastic modular sandwich 10 (i.e. sandwich structure) by continuous molding. Then, the thermoplastic skin layer 22 was treated by plasma (the gas used to generate plasma was air, the discharge power was 300 W, and the gas pressure was 0.3 kPa) for 30 s, twice, and the effective open time (i.e. the activation effective time after surface treatment) was 2 h, as shown in FIG. 4.

[0065] 3) The thermoset web flange 11 was prepared by using a small web flange mold, laying biaxial 800 fibers, using a vacuum infusion process, using epoxy 180 / 185 resin, and curing at 70°C.

[0066] 4) The thermoplastic modular sandwich 10 was placed on the platform, and the continuous thermoset web flange 11 was placed on both sides, fixed by vacuum bag, and bonded and cured by using epoxy adhesive to form the third intermediate layer 31, thereby obtaining a modular thermoplastic web. The surface pretreated thermoset-thermoplastic interface tensile shear performance was 38.4 MPa after testing.

[0067] Example 2: Continuous thermoset web flange 11 and plasma-treated thermoplastic modular sandwich 10 co-infusion.

[0068] 1) The thermoplastic prepreg tape 21 made of polypropylene was used to lay + / - 45° layers, and then the thermoplastic skin layer 22 was prepared by continuous molding.

[0069] 2) The thermoplastic skin layer 22, nylon film (i.e. second intermediate layer 24) and PET foam (i.e. core layer 23) were prepared into thermoplastic modular sandwich 10 by continuous molding.

[0070] 3) The thermoplastic skin layer 22 was treated by plasma (the gas used to generate plasma was air, the discharge power was 300 W, and the gas pressure was 0.3 kPa) for 30 s, twice, and the effective open time (i.e. the activation effective time after surface treatment) was 2 h, as shown in FIG. 4.

[0071] 4) As shown in FIG. 6, the thermoplastic skin layer 22 after treatment was laid on both sides of the small web flange mold (i.e. flange mold 40) by biaxial 800 fibers, and the thermoset web flange 11 was prepared by using a vacuum infusion process, using epoxy 180 / 185 resin, and curing at 70°C, while being consolidated with the thermoplastic modular sandwich 10 to obtain a modular thermoplastic web. The surface pretreated thermoset-thermoplastic interface tensile shear performance was 40.7 MPa after testing.

[0072] Example 3: Continuous hot solid web flange 11 co-infusion with sandblasted thermoplastic modular sandwich 10.

[0073] 1) Thermoplastic prepreg tape 21 of nylon material is used to prepare thermoplastic skin layer 22 by + / - 45° layering and then continuous molding.

[0074] 2) Thermoplastic skin layer 22, nylon adhesive film (i.e. second intermediate layer 24) and PET foam (i.e. core material layer 23) are prepared into thermoplastic modular sandwich 10 after continuous molding.

[0075] 3) As shown in FIG. 4, thermoplastic skin layer 22 is treated by sandblasting for 60s, 1 time, and the effective open time is 3h.

[0076] 4) As shown in FIG. 7, after the hot solid forming of the wind turbine blade shell, the thermoplastic modular sandwich is erected on the surface of the shell, and biaxial 800 fibers are laid on both sides of the treated thermoplastic skin layer 22. A hot solid web flange 11 is prepared by using a vacuum infusion process with epoxy 180 / 185 resin and a curing temperature of 70°C, and is simultaneously formed with the thermoplastic modular sandwich 10 to obtain a modular thermoplastic web. The test shows that the hot solid-thermoplastic interface tensile shear performance of the surface pretreated thermoplastic web is 38.9MPa.

[0077] Example 4: Continuous hot solid web flange 11 co-infusion with electron beam treated thermoplastic modular sandwich 10.

[0078] 1) Thermoplastic prepreg tape 21 of nylon material is used to prepare thermoplastic skin layer 22 by + / - 45° layering and then continuous molding.

[0079] 2) Thermoplastic skin layer 22, nylon adhesive film (i.e. second intermediate layer 24) and PET foam (i.e. core material layer 23) are prepared into thermoplastic modular sandwich 10 after continuous molding.

[0080] 3) As shown in FIG. 4, thermoplastic skin layer 22 is treated by electron beam (beam intensity of 10mA, electron beam energy of 1.8Mev) for 45s, 1 time, and the effective open time is 2h.

[0081] 4) As shown in FIG. 7, after the hot solid forming of the wind turbine blade shell, the thermoplastic modular sandwich is erected on the surface of the shell, and biaxial 800 fibers are laid on both sides of the treated thermoplastic skin layer 22. A hot solid web flange 11 is prepared by using a vacuum infusion process with epoxy 180 / 185 resin and a curing temperature of 70°C, and is simultaneously formed with the thermoplastic modular sandwich 10 to obtain a modular thermoplastic web. The test shows that the hot solid-thermoplastic interface tensile shear performance of the surface pretreated thermoplastic web is 39.3MPa.

[0082] Example 5: Continuous hot solid web flange 11 co-infusion with gamma ray treated thermoplastic modular sandwich 10.

[0083] 1) Thermoplastic prepreg tape 21 of nylon material is used to make thermoplastic skin ply 22 by + / - 45° layup and then continuous molding.

[0084] 2) Thermoplastic skin ply 22, nylon film (i.e. second intermediate layer 24) and PET foam (i.e. core material layer 23) are used to make thermoplastic modular sandwich 10 by continuous molding.

[0085] 3) As shown in FIG. 4, thermoplastic skin ply 22 is treated by gamma ray (irradiation energy of 3.5 MeV) for 45 s, 1 time, and the effective open time is 3 h.

[0086] 4) As shown in FIG. 7, after the wind turbine blade shell is hot solid formed, the thermoplastic modular sandwich is erected on the shell surface, biaxial 800 fibers are laid on both sides of the treated thermoplastic skin ply 22, and a hot solid web flange 11 is prepared by using a vacuum infusion process and using epoxy 180 / 185 resin with a curing temperature of 70°C, which is simultaneously solidified with the thermoplastic modular sandwich 10 to form a modular thermoplastic web, and a modular thermoplastic web is obtained. The peel shear performance of the hot solid-thermoplastic interface after surface pretreatment is 37.7 MPa.

[0087] Example 6: Continuous hot solid web flange 11 co-infusion with ultraviolet light treated thermoplastic modular sandwich 10.

[0088] 1) Thermoplastic prepreg tape 21 of nylon material is used to make thermoplastic skin ply 22 by + / - 45° layup and then continuous molding.

[0089] 2) Thermoplastic skin ply 22, nylon film (i.e. second intermediate layer 24) and PET foam (i.e. core material layer 23) are used to make thermoplastic modular sandwich 10 by continuous molding.

[0090] 3) As shown in FIG. 4, thermoplastic skin ply 22 is treated by ultraviolet light (wavelength of 350 nm, power of 25 W) for 100 s, 2 times, and the effective open time is 2 h.

[0091] 4) As shown in FIG. 7, after the wind turbine blade shell is hot solid formed, the thermoplastic modular sandwich is erected on the shell surface, biaxial 800 fibers are laid on both sides of the treated thermoplastic skin ply 22, and a hot solid web flange 11 is prepared by using a vacuum infusion process and using epoxy 180 / 185 resin with a curing temperature of 70°C, which is simultaneously solidified with the thermoplastic modular sandwich 10 to form a modular thermoplastic web, and a modular thermoplastic web is obtained. The peel shear performance of the hot solid-thermoplastic interface after surface pretreatment is 33.9 MPa.

[0092] The epoxy 180 / 185 resin used in the above comparative examples and examples is a two-component epoxy resin commonly used in the field for vacuum infusion of fan blades (i.e. TECHSTORM 180 / 185). In the actual implementation process, the person skilled in the art can also select other types or brands of epoxy resins, and can also select polyurethane resins, unsaturated polyesters and vinyl resins and other thermosetting resins.

[0093] As can be seen from the above, the surface pretreatment effect of the prepared thermoplastic modular sandwich is detected, which is divided into three experimental groups and six control groups. Among them, the control group is not pretreated, and the six experimental groups are pretreated under different parameter conditions.

[0094] As can be seen from the above, after the surface of the thermoplastic skin is pretreated by plasma and the like, the performance of the thermoset-thermoplastic interface is greatly improved, and then the thermoset web flange and the thermoplastic skin are connected and assembled by co-infusion or bonding to prepare the web for wind power.

[0095] It can be seen that the surface energy of the product can be significantly improved by the pretreatment method of the same nylon or polypropylene surface, thereby improving the thermoplastic and thermoset interface performance, and thereby realizing the production of the modular thermoplastic web. Therefore, the application adopts the combination of continuous thermoset flange and modular thermoplastic sandwich, and uses the continuous production method of the continuous molding equipment. On the one hand, the web sandwich can be continuously produced to effectively reduce quality defects; on the other hand, the continuous thermoset web flange can use smaller molds or utilize the blade shell to realize conventional bonding or co-infusion mode to complete the bonding with the shell and reduce the investment in molds; on the other hand, the use of efficient surface treatment technology can significantly improve the performance of the thermoset and thermoplastic interface to ensure the reliability of the product.

[0096] The above description of the embodiments is to facilitate the understanding and use of the application by those of ordinary skill in the art. Those skilled in the art can easily make various modifications to these embodiments, and apply the general principles described herein to other embodiments without having to go through creative labor. Therefore, the application is not limited to the above embodiments, and those skilled in the art can make improvements and modifications to the application within the scope of the application without departing from the scope of the application.

Claims

1. A modular thermoplastic web structure for wind turbine, comprising: continuous thermoset web flanges (11) fixedly connected with wind turbine blade shell; and thermoplastic modular sandwich (10) arranged between two continuous thermoset web flanges (11) and fixedly connected with the continuous thermoset web flanges (11) at the ends.

2. The modular thermoplastic web structure for wind power applications according to claim 1, wherein, The thermoplastic modular sandwich (10) comprises a core layer (23) in the middle and thermoplastic skin layers (22) covering the opposite sides of the core layer (23); The thermoplastic skin layers (22) are made of thermoplastic prepreg tapes (21), thermoplastic films, thermoplastic / thermoset hybrid fabrics or thermoplastic resin powders and dry fibers according to different layup structures.

3. The modular thermoplastic web structure for wind power applications according to claim 2, wherein, The thickness of the thermoplastic skin layers (22) is 1-10mm, and the thermoplastic resins used are one or more of polyimide, polyamide nylon, polycarbonate, polyether ketone, polyether ether ketone, polyether ketone ketone, polypropylene, polyethylene, polysulfone, polyvinyl chloride, polyurethane, polyacetal, polyether nitrile, polymethacrylate, polyphenylene sulfide, polylactic acid, polystyrene; The thermoplastic prepreg tapes (21) are one or more of unidirectional prepreg tapes, fabric prepreg tapes, twill prepreg tapes, biaxial or multi-axial prepreg tapes, with a thickness of 0.1-2mm and a fiber mass fraction of 40-95%; The thickness of the core layer (23) is 5-100mm, and the core material used is one or more of balsa wood, PET, PA, PVC, PU, PP, PC; The thermoplastic skin layers (22) and the core layer (23) are fixedly connected by welding, gluing or film gluing.

4. The modular thermoplastic web structure for wind power according to claim 2 or 3, wherein, The thermoplastic modular sandwich (10) comprises a plurality of unit modules, wherein the number of unit modules in the same position chord direction is not more than 5, and the adjacent two unit modules are connected by gluing or welding, and are reinforced and connected by the thermoplastic skin layer (22).

5. The modular thermoplastic web structure for wind power applications according to any one of claims 1 to 4, wherein, The cross section of the continuous thermoset web flange (11) is "π", "L" or "T" type, the angle is 60°-150°, the width is 50-250mm, and the profile of the continuous thermoset web flange is kept with the profile of the wind turbine blade shell; The opening width of the "π" type of the thermoset web flange exceeds the thermoplastic modular sandwich (10) by 0-10mm.

6. The modular thermoplastic web structure for wind power applications according to any one of claims 1 to 5, wherein, The thermoset web flange is formed by pouring or pultrusion of thermosetting resin and dry reinforcing fibers; The thermosetting resin is one of epoxy resin, polyurethane resin, unsaturated polyester and vinyl resin; The dry reinforcing fibers are one or more of glass fiber, ceramic fiber, metal fiber, carbon fiber, basalt fiber, regenerated fiber or synthetic fiber.

7. The modular thermoplastic web structure for wind power applications according to any one of claims 1 to 6, wherein, The continuous thermoset web flange (11) is continuous in the axial direction, or segmented according to the design structure of the wind turbine blade, and when the thermoset web flange is segmented, the production of each segment is continuous.

8. The modular thermoplastic web structure for wind power applications according to any one of claims 1 to 7, wherein, The thermoplastic modular sandwich (10) is also subjected to surface pretreatment, and the surface pretreatment is treated by one or more of plasma, ultraviolet irradiation, electron beam, sandblasting and γ-ray irradiation.

9. The method of manufacturing a modular thermoplastic web structure for wind power as claimed in any one of claims 1-8, comprising the steps of: (1) preparing a thermoplastic skin layer (22) using thermoplastic prepreg tapes (21), then combining the thermoplastic skin layer (22) with a core material layer (23) to obtain a thermoplastic modular sandwich (10), and cutting to the appropriate size; (2) preparing a continuous thermoset web flange (11) using thermoset resin and dry reinforcement fibers; (3) fixing the continuous thermoset web flange (11) to the thermoplastic modular sandwich (10) after surface pretreatment of the thermoplastic modular sandwich (10); or comprising the steps of: (A) preparing a thermoplastic skin layer (22) using thermoplastic prepreg tapes (21), then combining the thermoplastic skin layer (22) with a core material layer (23) to obtain a thermoplastic modular sandwich (10), and cutting to the appropriate size; (B) after surface pretreatment of the thermoplastic modular sandwich (10), laying dry reinforcement fibers in the area of the web flange mold and the thermoplastic modular sandwich (10), and then pouring and curing to form; or comprising the steps of: (I) preparing a thermoplastic skin layer (22) using thermoplastic prepreg tapes (21), then combining the thermoplastic skin layer (22) with a core material layer (23) to obtain a thermoplastic modular sandwich (10), and cutting to the appropriate size; (II) after surface pretreatment of the thermoplastic modular sandwich (10), laying dry reinforcement fibers in the area of the installation position of the wind blade shell and the thermoplastic modular sandwich (10), and then pouring and curing to form.

10. A wind power blade, comprising a wind blade shell, and a modular thermoplastic web structure for wind power as claimed in any one of claims 1-8.

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