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叶片制造装置/US9422916美国专利/auto/US9422916美国专利.md
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@ -37,7 +37,7 @@ Primary Examiner —Robert J Grun (51) Int.Cl. B29C 70/44 (2006.01) F03D1/06 (2
# ABSTRACT
A method for forming a profile for a hollow component is provided. A first composite fiber layer is laid out on a first surface corresponding to a first profile section of the component. A second composite fiber layer is laid out in a second surface corresponding to a second profile section of the component. A collapsed bag is laid out in onto the first composite fiber layer. The bag and the first composite fiber layer are fixed to the first surface. First and second mould elements are coupled such that the first surface and the second surface correspond to the first and second profiles. The bag is inflated such that the first composite fiber layer is pressed to the first surface and the second composite fiber layer is pressed to the second surface so that the first and second layers are coupled to form the profile.
提供了一种用于形成中空部件型材的方法。将第一复合纤维层铺设在对应于部件第一型材截面的第一表面上。将第二复合纤维层铺设在对应于部件第二型材截面的第二表面上。将一个塌陷的袋子铺设在第一复合纤维层上。将该袋子和第一复合纤维层固定到第一表面上。耦合第一和第二模具元件，使得第一表面和第二表面对应于第一和第二型材。对该袋子充气，使得第一复合纤维层被压向第一表面，并且第二复合纤维层被压向第二表面，从而使第一和第二层耦合以形成该型材。
![](images/bf081384b911d2f6583dd8dd5e62154199c069b34c5cb16c10838841353301a1.jpg)
8 Claims, 3 Drawing Sheets
@ -79,10 +79,12 @@ Wind turbine blades for wind turbine becoming larger and larger in size. Hence,
EP 1 310 351 A1 discloses a method for manufacturing blades for a wind turbine. A mould core is placed to a layer of glass fibre, which is laid in a mould part forming an underside of a blade. On top of the mould core, a further layer of glass fibre is laid. Finally, an upper mould part is laid over the mould core, so that the fibre layers that are pressed to the mould core form the profile of the blade.
# METHODFORMANUFACTURINGAWIND TURBINEROTORBLADE
风电机组叶片的尺寸越来越大。因此，现代风电机组叶片大多由复合纤维制成，特别是玻璃纤维制成。为了制造如此大的风电机组叶片，采用了多种制造方法，例如树脂传递模塑等。
EP 1 310 351 A1公开了一种用于制造风电机组叶片的方法。将模具型芯放置到一层玻璃纤维上，该玻璃纤维层铺设在一个构成叶片下侧的模具部件中。在模具型芯的顶部，铺设另一层玻璃纤维。最后，将一个上模具部件铺设在模具型芯上方，使得被压到模具型芯上的纤维层形成叶片的轮廓
After curing of the fibre layers in the mould parts, the mould core has to be removed, which may cause difficulties due to the large size of the wind turbine blades and due to the complex profiles of the wind turbine blades.
纤维层在模具部件中固化后，必须移除模具型芯，而这可能会因风电机组叶片尺寸大和型面复杂而造成困难。
# SUMMARY OF THEINVENTION
It may be an object of the present invention to simplify a manufacturing method for a wind turbine blade.
@ -93,31 +95,45 @@ According to a first aspect of the present invention, a method for forming a pro
The bag and the first composite fibre layer are fixed to the first mould surface. The first mould element is coupled to the second mould element in such a way, that the first mould surface and the second mould surface correspond to the profile of the hollow component (e.g. the wind turbine blade) to be manufactured. The bag is inflated in such a way, that the first composite fibre layer is pressed to the first mould surface and the second composite fibre layer is pressed to the second mould surface, so that the first composite fibre layer and the second composite fibre layer are coupled to form the profile of the hollow component to be manufactured.
5 According to a further exemplary embodiment, a blade for a wind turbine is presented, wherein the blade is manufactured by the above mentioned method.
According to a further exemplary embodiment, a blade for a wind turbine is presented, wherein the blade is manufactured by the above mentioned method.
Moreover, according to a further aspect of the present invention, a moulding system for applying the above menl0tioned method for the manufacturing hollow components made of composite fibre is presented.
The first mould element may be an upper mould part and the second mould element may be a lower mould part of a moulding device. The first mould element may comprise the
15 first mould surface, wherein the first mould surface forms for example a female mould of a first section of a profile of the hollow component to be formed. When laying a first composite fibre layer into the first mould element on the first mould surface, the first composite fibre forms the first profile section
20 of the hollow component. For example, if the first mould element is an upper half and the second mould element is a lower half, the first mould surface forms a female mould of the upper half of the hollow component (e.g. upper half of a blade) to be manufactured and the second mould surface
25 forms a female mould of the lower half of the component (lower half of the blade) to be manufactured. Beside this, the moulding device may comprise the first mould element, the second mould element and further mold elements, so that the mould surface is formed by the first mould surface, the second
30mould surface and the further mould surface, to which two or a plurality of individual composite fibre layers may be laid onto. In other words, the final profile of the component to manufactures may be divided in more than two profile sections.
35 The composite fibre layers may be formed with fibres in a uni-directional or multi-directional orientation with respect to each other. Moreover, the composite fibres may be provided in a web form, a woven form, such as a fibre mat or a prepreg. The first fibre layer may describe one or a plurality of
40fibre layers laid on top ofeach other located to the first mould element and the second fibre layer describes one or a plurality of fibre layers laid on top of each other located to the second mould element.
The first mould element may be an upper mould part and the second mould element may be a lower mould part of a moulding device. The first mould element may comprise the first mould surface, wherein the first mould surface forms for example a female mould of a first section of a profile of the hollow component to be formed. When laying a first composite fibre layer into the first mould element on the first mould surface, the first composite fibre forms the first profile section of the hollow component. For example, if the first mould element is an upper half and the second mould element is a lower half, the first mould surface forms a female mould of the upper half of the hollow component (e.g. upper half of a blade) to be manufactured and the second mould surface forms a female mould of the lower half of the component (lower half of the blade) to be manufactured. Beside this, the moulding device may comprise the first mould element, the second mould element and further mold elements, so that the mould surface is formed by the first mould surface, the second mould surface and the further mould surface, to which two or a plurality of individual composite fibre layers may be laid onto. In other words, the final profile of the component to manufactures may be divided in more than two profile sections.
The composite fibre layers may be formed with fibres in a uni-directional or multi-directional orientation with respect to each other. Moreover, the composite fibres may be provided in a web form, a woven form, such as a fibre mat or a prepreg. The first fibre layer may describe one or a plurality of fibre layers laid on top ofeach other located to the first mould element and the second fibre layer describes one or a plurality of fibre layers laid on top of each other located to the second mould element.
The composite fibres may comprise glass fibres, carbon 45fibres or other polymer fibre materials.
The bag is a flexible, i.e. inflatable and foldable, hollow body made for example of rubber or other elastic material.
The bag may be collapsible and inflatable. In a collapsed state, the bag is folded and minimized in size and in the 50 inflated state, the bag is maximized in size. The inflatable state ofthe bag may be achieved by blowing-in pressurized air inside the hollow bag or by applying underpressure at the environment ofthe bag. The bag is impermeable with respect to e.g. liquids i.e. resin and airtight.
The bag may be collapsible and inflatable. In a collapsed state, the bag is folded and minimized in size and in the inflated state, the bag is maximized in size. The inflatable state ofthe bag may be achieved by blowing-in pressurized air inside the hollow bag or by applying underpressure at the environment ofthe bag. The bag is impermeable with respect to e.g. liquids i.e. resin and airtight.
55 By the present invention a mould dorn to which composite fibre layers are placed in the prior art manufacturing methods may be obsolete and a hollow component, such as the blade of wind turbine, may be manufactured in one step. This is achieved by fixing (securing) the collapsed bag and the first
60 composite fibre layer to the first mould element. The fixing of the bag and the first composite fibre layer may be achieved by applying an adhesive (e.g. resin) or by providing underpressure between the bag and the first mould surface. Hence, when the bag and the first composite fibre layer is fixed to the
65 mould surface, the first mould element may be handled very simple and no slipping and relative movement of the first composite fibre layer with respect to the first mould surface is
By the present invention a mould dorn to which composite fibre layers are placed in the prior art manufacturing methods may be obsolete and a hollow component, such as the blade of wind turbine, may be manufactured in one step. This is achieved by fixing (securing) the collapsed bag and the first composite fibre layer to the first mould element. The fixing of the bag and the first composite fibre layer may be achieved by applying an adhesive (e.g. resin) or by providing underpressure between the bag and the first mould surface. Hence, when the bag and the first composite fibre layer is fixed to the mould surface, the first mould element may be handled very simple and no slipping and relative movement of the first composite fibre layer with respect to the first mould surface is caused, because the first composite fibre layer is pressed on the first mould surface by the bag. For this reason, the first mould element may be turned overhead without a falling-out of the bag and the first composite fibre layer out of the first mould element. Hence, the first mould element and the second mould element may be assembled easily and later after a coupling of both mould elements, finalizing steps, such as resin injection or curing may be applied for finalizing the profile of the component to be formed.
# US 9,422,916 B2
本发明的一个目的可能是简化风电机组叶片的制造方法。
caused, because the first composite fibre layer is pressed on the first mould surface by the bag. For this reason, the first mould element may be turned overhead without a falling-out of the bag and the first composite fibre layer out of the first mould element. Hence, the first mould element and the second mould element may be assembled easily and later after a coupling of both mould elements, finalizing steps, such as resin injection or curing may be applied for finalizing the profile of the component to be formed.
该目的通过一种用于制造复合纤维中空部件（特别是风电机组中空叶片）的型材成型方法、一种风电机组叶片以及一种用于根据独立权利要求应用该方法的模塑系统来解决。
根据本发明的第一方面，提出了一种用于制造复合纤维中空部件（特别是风电机组中空叶片）的型材成型方法。根据该方法，将第一复合纤维层铺设在第一模具元件的第一模具表面上，其中第一模具表面对应于待制造中空部件的第一型材截面。将第二复合纤维层铺设在第二元件的第二模具表面中，其中第二模具表面对应于待制造中空部件的第二型材截面。将一个处于塌陷状态的袋子铺设在第一复合纤维层上。
袋子和第一复合纤维层固定在第一模具表面上。第一模具元件以这样的方式与第二模具元件耦合，使得第一模具表面和第二模具表面对应于待制造中空部件（例如风电机组叶片）的型材。袋子以这样的方式充气，使得第一复合纤维层被压向第一模具表面，第二复合纤维层被压向第二模具表面，从而使第一复合纤维层和第二复合纤维层耦合以形成待制造中空部件的型材。
根据另一个示例性实施例，提出了一种风电机组叶片，其中该叶片通过上述方法制造。
此外，根据本发明的另一个方面，提出了一种用于应用上述方法制造复合纤维中空部件的模塑系统。
第一模具元件可以是模塑装置的上模部分，第二模具元件可以是下模部分。第一模具元件可以包括第一模具表面，其中第一模具表面例如形成待成形中空部件型材的第一截面的阴模。当将第一复合纤维层铺设到第一模具元件的第一模具表面上时，第一复合纤维形成中空部件的第一型材截面。例如，如果第一模具元件是上半部分，第二模具元件是下半部分，则第一模具表面形成待制造中空部件（例如叶片的上半部分）上半部分的阴模，第二模具表面形成待制造部件（叶片的下半部分）下半部分的阴模。除此之外，模塑装置可以包括第一模具元件、第二模具元件和进一步的模具元件，使得模具表面由第一模具表面、第二模具表面和进一步的模具表面形成，可以在其上铺设两个或多个单独的复合纤维层。换句话说，待制造部件的最终型材可以被分成两个以上的型材截面。
复合纤维层可以由彼此呈单向或多向取向的纤维形成。此外，复合纤维可以以网状形式、编织形式（例如纤维毡或预浸料）提供。第一纤维层可以指位于第一模具元件的一个或多个相互堆叠的纤维层，第二纤维层可以指位于第二模具元件的一个或多个相互堆叠的纤维层。
复合纤维可以包括玻璃纤维、碳纤维或其他聚合物纤维材料。
该袋子是一种柔性中空体，即，可充气和可折叠的，例如由橡胶或其他弹性材料制成。
该袋子可以是可塌陷和可充气的。在塌陷状态下，袋子折叠并尺寸最小化；在充气状态下，袋子尺寸最大化。袋子的充气状态可以通过向中空袋内吹入加压空气或通过在袋子周围施加负压来实现。该袋子对例如液体（即树脂）不渗透且气密。
通过本发明，在现有技术制造方法中用于放置复合纤维层的模具芯棒可以被淘汰，并且中空部件（例如风电机组的叶片）可以一步制造。这通过将塌陷的袋子和第一复合纤维层固定（紧固）到第一模具元件来实现。袋子和第一复合纤维层的固定可以通过施加粘合剂（例如树脂）或通过在袋子和第一模具表面之间提供负压来实现。因此，当袋子和第一复合纤维层固定在模具表面上时，第一模具元件可以非常简单地操作，并且不会引起第一复合纤维层相对于第一模具表面的滑动和相对移动，因为第一复合纤维层被袋子压在第一模具表面上。因此，第一模具元件可以翻转而袋子和第一复合纤维层不会从第一模具元件中掉出。因此，第一模具元件和第二模具元件可以容易地组装，并且在两个模具元件耦合之后，可以应用最终步骤，例如树脂注射或固化，以最终确定待成形部件的型材。
By the prior art manufacturing methods, a massive dorn is put to a composite fibre layer in a mould element and later the second composite fibre layer has to be placed on top of the massive dorn. Finally, the second mould element is coupled to the first mould element, wherein there is a risk that the second composite fibre layer slips away. Moreover, the adjustment of all parts in the mould element is complex. With the presented inventive method, the first composite fibre layer and the inflatable bag are already fixed and aligned to the first mould element before the first mould element is coupled to the second mould element. For this reason, a slipping of the first composite fibre layer with respect to the first mould element may be prevented. A pressing of the composite fibre layers to the surfaces of the mould elements may be accomplished by the inflatable bag. For the fixing of the bag and the first composite layer to the upper first mould element, a massive dorn may be obsolete.
@ -131,6 +147,17 @@ According to a further exemplary embodiment, the first composite layer is larger
According to a further exemplary embodiment, the coupling of the first mould element to the second mould element comprises an adjusting of the first mould element to the second mould element in such a way, that the surplus section overlaps partially with the second composite fibre layer in the second mould element. Hence, the contact areas (interface sections) between the first composite fibre layer and the second composite fibre layer may be reinforced, so that a more robust component may be manufactured. Thereby, during the adjustment of the first mould elements to the second mould elements, the surplus section is bended to the inside into a cavity formed between the coupled mould elements, so that the surplus section overlaps with the second composite fibre layer.
通过现有制造方法，将一个巨型芯棒放置在模具元件中的复合纤维层上，随后必须将第二复合纤维层放置在巨型芯棒的顶部。最后，将第二模具元件耦合到第一模具元件，其中存在第二复合纤维层滑脱的风险。此外，模具元件中所有部件的调整很复杂。通过本发明方法，在第一模具元件耦合到第二模具元件之前，第一复合纤维层和充气袋已经固定并对准到第一模具元件。因此，可以防止第一复合纤维层相对于第一模具元件滑脱。复合纤维层压向模具元件表面可以通过充气袋实现。为了将充气袋和第一复合层固定到上部第一模具元件，巨型芯棒可能不再需要。
此外，在复合纤维层固化后，充气袋可以塌陷并因此再次缩小尺寸，从而可以容易地从制造的空心部件的内腔中取出充气袋。
如果制造一个复杂部件，例如风电机组的叶片，该叶片例如沿其长度方向扭曲，则这是有益的。通过风电机组叶片的这种扭曲，传统的巨型芯棒难以移除。通过充气袋，可以实现从最终成型的风电机组叶片内腔中轻松取出充气袋。
根据本发明的另一示例性实施例，充气袋的固定是通过抽吸充气袋与第一模具表面之间的空气来实现的，使得充气袋和第一复合纤维层通过负压（即真空）固定到第一模具表面。因此，通过本示例性实施例，当停止抽吸空气时，充气袋可以容易地被移除。此外或可选地，充气袋和/或第一复合层例如可以通过粘合剂（例如树脂）固定到第一模具表面。来自外部的额外固定压力，例如通过巨型芯棒施加的压力，可能不再需要。
根据另一示例性实施例，第一复合层大于第一模具表面，使得第一复合纤维层形成一个超出第一模具表面边缘的余量部分。该余量部分描述了过长的长度、悬伸或突出部分。通过特别在第一复合纤维层的边缘区域使用余量部分，可以实现第二复合纤维层与模具元件边缘的重叠，这些边缘定义了第一模具表面的区域，且该区域的尺寸与相应型材部分的尺寸相对应。该余量部分是可移动的（例如可折叠的），并且不通过充气袋固定到第一模具表面。
根据另一示例性实施例，第一模具元件与第二模具元件的耦合包括将第一模具元件调整到第二模具元件，使得余量部分与第二模具元件中的第二复合纤维层部分重叠。因此，第一复合纤维层和第二复合纤维层之间的接触区域（界面部分）可以得到加强，从而可以制造出更坚固的部件。因此，在将第一模具元件调整到第二模具元件的过程中，余量部分向内弯曲到耦合模具元件之间形成的腔体中，使得余量部分与第二复合纤维层重叠。
In another exemplary embodiment ofthe present invention, the adjusting comprises an arranging of the first mould element in such a way that the surplus section is aligned in a
10 predetermined position by gravity. Next, the first mould element is brought together with the second mould element, wherein, when the surplus section is in the predetermined position, the surplus section overlaps partially with the sec
15 ond composite fibre layer in the second mould element. For example, if the first mould element is turned overhead, the surplus section, which is not fixed to the first mould element, is aligned in a proximately vertical orientation, because of gravity. When bringing together the first mould element and