Multi-chamber Fiber Composite Blade with Orthogonal Walls
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Solution Overview
Problem
Existing fiber composite material blades for wind turbine generators face issues such as high weight, insufficient strength, poor seismic performance, large starting torque, and high maintenance costs due to their solid or hollow structures.
Innovation Solution
An orthogonal structural member in a multi-chamber fiber composite material is developed, featuring a fan-shaped or plate-shaped structure with integrated fiber shells and foam plastic cores, formed through a thermal molding process. This design includes multiple chambers with orthogonal chamber walls, enhancing mechanical strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid or hollow structures are used for fiber composite material blades, then the structural simplicity is maintained, but the mechanical strength and seismic performance are insufficient
Solution Approach 1:
The blade is divided into multiple independent chambers (first chamber, second chamber, third chamber, etc.) separated by partition walls, with each chamber containing independent foam plastic cores. This segmentation provides multiple load-bearing paths, significantly improving mechanical strength and seismic performance while maintaining reasonable structural complexity through systematic design
Solution Approach 2:
The blade combines fiber composite material shells with foam plastic core materials to form a composite structure. The fiber composite material provides high strength-to-weight ratio and corrosion resistance, while the foam plastic cores provide structural support and vibration damping, achieving synergistic enhancement of mechanical properties
2Stability of the object's composition
If multi-chamber structure with orthogonal chamber walls is adopted, then the mechanical strength and stability are improved, but the manufacturing complexity increases
Solution Approach 1:
The mold is pre-designed with precise orthogonal partition walls and chamber structures before manufacturing. The mold includes first mold halves and second mold halves with integrated cavity structures that define the multi-chamber configuration, allowing the blade to be formed with complex internal geometry in a single molding operation, thus simplifying the actual manufacturing process
Solution Approach 2:
The manufacturing process combines the formation of multiple chambers, partition walls, and foam plastic cores into a single integrated molding operation. The fiber composite material shell and foam plastic cores are formed simultaneously in one process step, reducing the number of manufacturing steps and simplifying production despite the complex final structure
3Object-affected harmful factors
If foam plastic cores are used in chambers, then the vibration and noise are reduced, but the weight of the blade increases
Solution Approach 1:
Foam plastic cores with porous internal structures are used within the chambers. These porous materials provide effective vibration damping and noise reduction through their cellular structure that dissipates vibrational energy, while maintaining relatively low density to minimize the weight increase of the overall blade structure
4Productivity
If the blade structure is optimized for high wind speed operation, then the power generation efficiency at high wind speed improves, but the starting torque increases
Solution Approach 1:
Different portions of the blade are designed with locally optimized characteristics: the root portion has thicker walls and stronger structural support to reduce starting torque and withstand high root bending moments, while the tip portion has optimized aerodynamic profiles for efficient wind energy capture at higher speeds. The multi-chamber structure allows different sections to have tailored structural properties
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The multi-chamber fiber composite material blades exhibit improved mechanical strength, reduced vibration and noise, enhanced stability, and a lower starting torque, enabling efficient wind energy capture across various wind speeds and reducing maintenance costs.
Implementation Method 1
the temperature of a die cavity is increased, under the effect of expansion pressure of the foaming material, the chamber walls and the structural panels are synchronously formed
Implementation Method 2
the foaming material in the preformed core bodies expands and fills each chamber, so as to form a multi-chamber space structure
Implementation Method 3
integrally forming a fiber shell and a core structure, wherein the temperature of a die cavity is increased, under the effect of expansion pressure of the foaming material, the chamber walls and the structural panels are synchronously formed
Data Source
AI summary
The present invention belongs to the technical field of processing and manufacturing of fiber composite material, and particularly relates to an orthogonal structural member in a multi-chamber fiber composite material, a manufacturing process and a film material. An orthogonal structural member in a multi-chamber fiber composite material includes a shell comprising structural panels and at least two chambers formed between the structural panels, wherein chamber walls are arranged between every two adjacent chambers, and are perpendicular to the structural panels; the shell and the chamber walls are made of carbon fiber material or glass fiber material; each chamber is provided with a core made of foam plastic; and the structural panels, the chambers, the chamber walls and the cores are integrally formed through a thermal forming process of fiber material and foam plastic. The manufacturing process includes the steps of preparing preformed core bodies, performing die-filling on the preformed core bodies, and integrally forming a fiber shell and a core structure. The orthogonal structural member in the multi-chamber fiber composite material has the technical effects of high strength, low weight, good stability, high applicability and the like.