CN102753345A - 多层结构在风力发电站中的应用 - Google Patents

多层结构在风力发电站中的应用 Download PDF

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CN102753345A
CN102753345A CN2010800565242A CN201080056524A CN102753345A CN 102753345 A CN102753345 A CN 102753345A CN 2010800565242 A CN2010800565242 A CN 2010800565242A CN 201080056524 A CN201080056524 A CN 201080056524A CN 102753345 A CN102753345 A CN 102753345A
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D·帕斯曼
K·弗兰肯
S·林德纳
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Abstract

本发明涉及多层结构在风力发电站转子叶片的制造中的应用，以及用于风力发电站的转子叶片。

Description

多层结构在风力发电站中的应用
技术领域
本发明涉及多层结构(Schichtaufbauten)在风力发电站用的转子叶片的制造中的应用以及风力发电站用的转子叶片。
背景技术
风能正变得日益重要，因此，风力发电站、特别是转子叶片及其制造得到了广泛的研究和进一步的发展。其中，主要关注所制造的转子叶片的质量和成本有利的制造。迄今已知的风力发电站用的转子叶片是由基于树脂作为基质材料如聚酯树脂(UP)、乙烯基酯树脂(VE)、环氧树脂(EP)的纤维增强的塑料构成。主要这样来制造叶片，即在每一情况下以单块制造下半叶片和上半叶片。然后彼此相叠地置放两个半片叶片并且将它们胶粘。斜撑或弦杆被一起粘合以便加固。
在半片叶片的制造中，首先制造必须完全固化的纤维复合材料。固化工序十分耗时，对于整体的快速生产是不利的。由上述树脂制成的风力发电站用转子叶片通常是通过手工层压、通过预浸料技术辅助的手工层压、通过缠绕法或真空辅助浸渍法制成。在手工层压中，先通过将脱模剂和/或任选地将胶衣(Gelcoat)施加到模具表面，以准备模具。接着，相继将单向或二轴向取向的玻璃纱网(Glasgelege)放置在模具中。然后把树脂施加到纱网上并且手动通过辊子压入纱网中。该步骤可以适宜地经常重复。另外还可以加入作为加固材料的弦杆以及其他部件例如避雷装置。在第一层玻璃纤维强化层上施加所谓的隔片层，通常由西印度轻木、聚氯乙烯(PVC)泡沫或聚氨酯(PUR)泡沫构成，并且涂覆与第一层类似的第二层玻璃纤维强化层。尽管这种方法具有以下优势，即机器投资低，误差识别和可能的修正方法简单，然而，制造的人工成本过于高昂，因此，该方法的成本极高，并且长的制造时间还会带来更多的误差和为确保质量更大的投入。
通过预浸料技术辅助的手工层压法与简单的手工层压法类似。其中，除模具外，还要制造所谓的预浸料(用树脂浸渍而预先制备的玻璃丝网(Glasmatte))，并将其定位在转子叶片模具中。尽管相对于简单手工层压而进行的用于制造预浸料的半自动化会给转子制造带来更佳的质量恒定性，然而，为了保护作业人员不受到液态的树脂混合物所含的易挥发的化合物的危害，也需要不可忽视的投入(工作场所安全性等)。
在树脂注射法(也被称为“树脂传递模塑”(RTM)或“真空辅助树脂传递模塑”(VA RTM)或“SCRIMP工艺”(Seemann复合树脂浸渍模塑工艺)中，通过施加脱模剂和可能的胶衣来准备模具。接着，按照精确的制造计划将干燥的纤维垫置在模具中。第一插入层之后提供了转子叶片的向外置放的层。然后，置入间隔材料，再在其上放置纤维垫，其进而构成制成的半个转子/半个转子叶片的内层。再用真空密封的膜严密地密封整个模具。在于各个位置将树脂注射进模具(薄膜与模具之间的空间)前，从所准备的模具中的纤维垫和间隔材料中抽出空气。这一方法具有-如上述两个方法-以下不足，即在构件脱模前所必需的固化时间极长，为多达12小时，因此大大限制了设备的生产率。
发明内容
因此，本发明所基于的目的在于，提供转子叶片，其既不存在上述不足，同时也能成本有利的在更短的时间内制成。
出人意料地，上述目的可由此实现，即以聚氨酯替代上述树脂作为塑料来制造转子叶片。根据本发明，特别是在转子叶片的外壳中使用聚氨酯作为塑料；外壳中所用的纤维层被施加这种材料。
本发明涉及风力发电站的转子叶片，其具有至少部分地由具有下列层的多层结构构成的外壳：
a)脱模剂层
b)任选的胶衣层
c)经过塑料处理的纤维层
d)任选的隔片层
e)配有塑料的纤维层
f)任选的塑料膜
并且其特征在于，将聚氨酯用作所述塑料。
本发明还涉及一种用于制造根据本发明的风力发电站用的转子叶片的方法，所述叶片具有至少部分地由具有下列层的多层结构构成的外壳：
a)脱模剂层
b)任选的胶衣层
c)经过塑料处理的纤维层
d)任选的隔片层
e)配有塑料的纤维层
f)任选的塑料膜
其特征在于，所述纤维层用供制造作为塑料的聚氨酯用的反应混合物处理。
本发明还涉及多层结构在风力发电站用的转子叶片的制造中的应用，其中的多层结构包括下列层：
a)脱模剂层
b)任选的胶衣层
c)经过塑料处理的纤维层
d)任选的隔片层
e)配有塑料的纤维层
f)任选的塑料膜
其特征在于，将聚氨酯用作塑料。
优选将含硅或含蜡的脱模剂用于脱模剂层。这由文献中已知。
胶衣层优选由聚氨酯树脂、环氧树脂、不饱和聚酯树脂或乙烯基酯树脂构成。
可优选将玻璃纤维乱丝层、玻璃纤维织物和玻璃纤维纱网、裁断或碾碎的玻璃纤维或矿物纤维以及基于聚合物纤维、矿物纤维、碳纤维、玻璃纤维或芳纶纤维的纤维垫、纤维非织造物与纤维针织物及其混合物、特别优选将玻璃纤维垫或玻璃纤维非织造物用作纤维层。优选将塑料泡沫、木材或金属用作隔片层。
任选使用的塑料膜可以在转子叶片的制造中保留下来作为外壳中的层，或者其可在半个转子叶片脱模时除去。塑料膜尤其用于在填充液态的树脂混合物前在真空抽吸的制造工序中密封模具半壳，其中所述模具半壳已经设有上述层。
使用聚氨酯作为塑料。通过具有至少两个对异氰酸酯呈反应性的氢原子的化合物与多异氰酸酯的反应可得到聚氨酯。由异氰酸酯组份和具有至少两个对异氰酸酯呈反应性的氢原子的化合物组成的反应混合物被注入预先准备的已抽真空的多层结构中。
通常考虑使用这样的化合物作为具有至少两个对异氰酸酯呈反应性的氢原子的化合物，其在分子中带有两个或更多个反应性基团，例如OH基团、SH基团、NH基团、NH2基团以及CH酸基团。优选使用聚醚多元醇和/或聚酯多元醇，尤其优选使用聚醚多元醇。多元醇制剂优选作为多元醇包含这样的多元醇，其具有200至1830mg KOH/g的、优选300至1000mg KOH/g、尤其优选为350至500mg KOH/g的羟值。多元醇的粘度优选≤800mPas(在25℃)。优选多元醇具有至少60％的仲羟基，优选至少80％的仲羟基，尤其优选为90％的仲羟基。尤其优选基于环氧丙烷的聚醚多元醇。
使用常见的脂肪族的、脂环族以及特别是芳香族的二异氰酸酯和/或多异氰酸酯作为多异氰酸酯组份。合适的多异氰酸酯的实例为1，4-亚丁基二异氰酸酯、1，5-戊烷二异氰酸酯、1，6-六亚甲基二异氰酸酯(HDI)、异佛尔酮二异氰酸酯(IPDI)、2，2，4-和/或2，4，4-三甲基六亚甲基二异氰酸酯、双(4，4‘-异氰酸根合环己基)甲烷或其与其他异构体的混合物、1，4-亚环己基二异氰酸酯、1，4-苯二异氰酸酯、2，4-和/或2，6-甲苯二异氰酸酯(TDI)、1，5-萘二异氰酸酯、2，2‘-和/或2，4‘-和/或4，4‘-二苯基甲烷二异氰酸酯(MDI)和/或其高级同系物(pMDI)、1，3和/或1，4-双-(2-异氰酸根合丙-2-基)-苯(TMXDI)、1，3-(双异氰酸根合甲基)苯(XDI)。优选用二苯基甲烷二异氰酸酯(MDI)、特别是由二苯基甲烷二异氰酸酯与多苯基多亚甲基多异氰酸酯(pMDI)组成的混合物作为异氰酸酯。所述由二苯基甲烷二异氰酸酯与多苯基多亚甲基多异氰酸酯(pMDI)组成的混合物优选的单体含量为40至100重量％，优选为50至90重量％，尤其优选为60至80重量％。所用的多异氰酸酯的NCO含量应优选超过25重量％，优选超过30重量％，尤其优选超过31.4重量％。使用的MDI优选应具有共至少3重量％，优选为至少20重量％，尤其优选至少40重量％的2，2’-二苯基甲烷二异氰酸酯与2，4’-二苯基甲烷二异氰酸酯的总含量。异氰酸酯的粘度应优选为≤250mPas(在25℃)，优选≤100mPas(在25℃)，尤其优选为≤50mPas(在25℃)。
优选除了已知的反应性组分与添加剂和添加物外，聚氨酯反应混合物优选还包含填料如碳纳米管、硫酸钡、二氧化钛、短玻璃纤维或者天然纤维状或薄片状矿物例如硅灰石或白云母。优选将消泡剂、催化剂与潜催化剂用作添加剂和添加物。还可根据需要使用其他已知的添加剂和添加物。
合适的聚氨酯体系尤其指那些透明的聚氨酯体系。因为在制造较大的成型件时，低粘度对于模具的均匀填充是必需的，所以尤其合适的是其粘度≤5000mPas(在25℃；组份混合后30分钟)，优选≤2000mPas，尤其优选1000mPas的聚氨酯体系。优选这样来选择异氰酸酯组份和具有至少两个对异氰酸酯呈反应性的氢原子的化合物之间的反应比例，使得在反应混合物中，异氰酸酯基团的数量与对异氰酸酯呈反应性的基团的数量之间的比为0.9至1.5，优选1.0至1.2，尤其优选1.02至1.1。
在一个优选实施方案中，由异氰酸酯组份与具有至少两个对异氰酸酯呈反应性的氢原子的化合物组成的反应混合物在20至80℃、尤其优选在25至40℃的温度被注射。
当充填反应混合物后，可通过加热模具来加速聚氨酯的固化。在一种优选实施方案中，被注射的由异氰酸酯组份与具有至少两个对异氰酸酯呈反应性的氢原子的化合物组成的反应混合物在40至160℃、优化在60至120℃、尤其优选在70至90℃的温度固化。
打算借助以下实施例进一步说明本发明。
具体实施方式
实施例
由各种聚氨酯体系制成成型件(板)并且与标准物环氧树脂体系相比较。板的大小为17cm×17cm，厚度为4mm。
脱模时间为这样的时间，在该时间后PUR样品能够不变形地从板材模具中手动取出。
在组份混合后的30分钟确定粘度，因为在制造较大的成型件时为了均匀填充模具需要一定时长的低粘度。
实施例1
在室温下将70g的Baygal
Figure BPA00001577295800051
K 55(Bayer MaterialScience AG公司的聚醚多元醇；羟值：385±15mg KOH/g；25℃时的粘度：600±50mPas)与65.3g的Baymidur
Figure BPA00001577295800052
K 88(Bayer MaterialScience AG公司的产品；二苯基甲烷二异氰酸酯与多苯基多亚甲基多异氰酸酯的混合物；NCO含量为31.5±0.5重量％；25℃时的粘度：90±20mPas)搅拌并且以减压脱气。将溶液注入板材模具并且在室温放置一个小时。然后将样品温度调节至80℃。凝胶化时间约为70分钟，脱模时间为两个小时。
样品具有76肖氏D的硬度。
25℃时的粘度在组份混合后30分钟为1540mPas。
实施例2
在室温下将70g的Baygal
Figure BPA00001577295800061
K 55(Bayer MaterialScience AG公司的聚醚多元醇；羟值：385±15mg KOH/g；25℃时的粘度：600±50mPas)与63g的BaymidurVP.KU 3-5009(Bayer MaterialScience AG公司；二苯基甲烷二异氰酸酯与多苯基多亚甲基多异氰酸酯；NCO含量为31.5至33.5重量％；25℃时的粘度：15至30mPas)搅拌并且以减压脱气。将溶液注入板材模具并且在室温放置一个小时。然后将样品温度调节至80℃。脱模时间为两个小时。
样品具有76肖氏D的硬度。
25℃时的粘度在组份混合后30分钟为974mPas。
对比例3
在室温下将180g的浸渍树脂Larit RIM 135(L-135i)(Lange+Ritter公司的产品)与60g的固化剂Larit RIMH 137(Lange+Ritter公司的产品)搅拌并且以减压脱气。将溶液注入板材模具并且在室温放置一个小时。然后将样品温度调节至80℃。脱模时间为12个小时。
样品具有76肖氏D的硬度。
聚氨酯体系的脱模明显更快。由于可大大缩短模具的占用时间，进而能制造更多的成型体，所以聚氨酯体系更快的脱模时间能实现更高的生产率。

Claims (8)

1.多层结构在风力发电站用的转子叶片的制造中的应用，其中，所述多层结构具有下列层：
g)脱模剂层
h)任选的胶衣层
i)经塑料处理的纤维层
j)任选的隔片层
k)配有塑料的纤维层
l)任选的塑料膜
其特征在于，将聚氨酯用作塑料。
2.风力发电站用的转子叶片，其具有至少部分地由具有下列层的多层结构构成的外壳：
a)脱模剂层
b)任选的胶衣层
c)经塑料处理的纤维层
d)任选的隔片层
e)配有塑料的纤维层
f)任选的塑料膜
其特征在于，将聚氨酯用作塑料。
3.用于制造根据权利要求2所述的风力发电站用的转子叶片的方法，其具有至少部分地由具有下列层的多层结构构成的外壳：
a)脱模剂层
b)任选的胶衣层
c)经塑料处理的纤维层
d)任选的隔片层
e)配有塑料的纤维层
f)任选的塑料膜
其特征在于，所述纤维层经制造作为塑料的聚氨酯用的反应混合物处理。
4.根据权利要求3所述的方法，其特征在于，所述反应混合物包含作为异氰酸酯的NCO含量大于25重量％的二苯基甲烷二异氰酸酯和/或多亚苯基多亚甲基多异氰酸酯。
5.根据权利要求3所述的方法，其特征在于，所述反应混合物包含作为具有至少两个对异氰酸酯呈反应性的氢原子的化合物的聚醚多元醇，其中，至少60％的OH基团为仲羟基并且具有200至1830mg KOH/g的羟值。
6.根据权利要求3所述的方法，其特征在于，在20至80℃的温度将所述反应混合物施加到所述纤维层中。
7.根据权利要求3所述的方法，其特征在于，所述反应混合物在40℃至160℃的温度固化。
8.根据权利要求3所述的方法，其特征在于，所述反应混合物的粘度在混合后30分钟≤5000mPas。
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