JP6714405B2 - Rotor blade and manufacturing method thereof - Google Patents

Description

The present invention relates to a rotor blade for a wind turbine and a method for manufacturing the same, and more particularly to a rotor blade in which a lift-type blade is lightened by using a combination of a plurality of hollow blocks, and a method for manufacturing the rotor blade.

The vertical blade of the vertical axis wind turbine is generally formed of a hard synthetic resin, and even a large blade has a core made of a foamed synthetic resin molded body and a surface layer formed on the surface (for example, Patent Document 1). ..

JP, 2003-206848, A

In the blade as described in Patent Document 1, for example, a large blade having a chord length of 1 m or more and a height of 5 m or more makes it difficult to mold the foamed synthetic resin and may cause foaming unevenness. Therefore, if the strength of the surface layer by FRP is increased, the weight of the whole becomes heavy, and it becomes difficult to increase the rotation efficiency.
It is an object of the present invention to provide a rotor blade which is light in weight and excellent in rigidity without using a foamed synthetic resin for a core, and a manufacturing method thereof.

The specific contents of the present invention are as follows.

(1) A lift-type blade for a wind turbine, in which resin linear bodies extruded from a plurality of nozzles are lowered for each block-shaped mold in which the blade is divided into a plurality of blocks, and a plurality of resins are lowered in the lowering process. A three-dimensional network in which a linear body forms an infinite number of continuous irregular loop-shaped portions in the longitudinal direction, and the loop-shaped portions are adhered to each other in a mold to form innumerable irregular voids. Rotor blades in which a plurality of three-dimensional mesh blocks are combined in a blade shape, adhered and integrated, and a coating layer is applied to the entire surface thereof .

( 2 ) In the three-dimensional mesh block, a single wire of a plurality of resin linear bodies forms irregular connecting rings in all directions in the mold and is adhesively hardened adjacent to each other to form an inner shape of the mold. The rotor blade according to (1) above, which is formed on the .

( 3 ) The rotor blade according to (1) or (2 ) above, wherein the three-dimensional mesh blocks are vertically long and arranged in parallel in the chord direction so as to be integrally connected in a blade shape .

( 4 ) The rotor blade according to (3), wherein the three-dimensional mesh block is a tubular body oriented in a vertical direction, and a plurality of the blocks are combined in a chord direction and bonded in a blade shape .

( 5 ) The rotor blade according to any one of (1) to (4), wherein the three-dimensional mesh blocks are bonded to each other in a blade shape by interposing a thin plate-shaped rib on a bonding facing surface between adjacent blocks .

( 6 ) In the three-dimensional mesh block, the rotor according to any one of (1) to (5), wherein a foamed resin is filled in a three-dimensional mesh-like gap between resin linear bodies forming the three-dimensional mesh block. blade.

( 7 ) In a method for manufacturing a lift type blade of a wind turbine, a block-shaped mold is formed by dividing the blade shape into a plurality of blocks, and the resin linear body extruded from a plurality of nozzles is lowered for each mold. In the descending process, a plurality of resin linear bodies form an infinite number of continuous irregular loop-shaped portions in the longitudinal direction, and the loop-shaped portions are adhered to each other in the form frame to form an infinite number of imperfections. A method for producing a rotor blade, comprising forming a three-dimensional mesh block having a regular void, combining a plurality of the three-dimensional mesh blocks into a blade shape and integrating them, and depositing a coating layer on the entire surface thereof .

According to the present invention, the following effects can be obtained.

In the invention described in (1) above, since the three-dimensional net-like block has a plurality of resin linear bodies bent and adhered to each other, the resin linear bodies are irregular in appearance, like a loofah core. Even though the block is bulky, it has a large space and is therefore lightweight as a whole.
The specific gravity of the synthetic resin used for it is light enough to float on water, has elasticity, and is excellent in rigidity. Therefore, when the surface layer is integrally formed on the surface, it is less likely to break even in strong winds such as typhoons. Further, even if it is bent, it is difficult to be cut, so damage to humans and animals is unlikely to occur.

In the invention described in ( 2 ) above, in the three-dimensional mesh block , a single wire of a plurality of resin linear bodies forms irregular connecting rings in all directions in a mold and is adhesively cured adjacent to each other. Since it is formed in the inner shape of the mold, it can be manufactured quickly. And since the three-dimensional mesh block is connected with the wire rods having a large number of connecting rings, it is excellent in elasticity, it is excellent in restoring property against bending, and it is possible to obtain a blade having excellent overall rigidity. it can.

In the invention described in ( 3 ) above, a plurality of vertically elongated three-dimensional net-like blocks are arranged in parallel in the chord direction and integrally joined, so that the invention can be manufactured quickly. In addition, the three-dimensional mesh block has resin linear bodies having a large number of connecting rings, so it has excellent elasticity, excellent resilience to bending, and a blade with excellent overall rigidity. You can

In the invention described in ( 4 ) above, the three-dimensional mesh block is formed in a tubular shape, and when a plurality of these blocks are arranged in parallel and connected to each other to form a blade, the blade has excellent rigidity, but a blade with many gaps. Can be formed. If necessary, the hollow portion of the tube can be filled with a foamed synthetic resin to increase the strength.

In the invention described in ( 5 ) above , since ribs are provided between the three-dimensional mesh blocks, even if the blade receives a centrifugal force at the time of rotation, it is possible to prevent bending in the radial direction of rotation. And has excellent rigidity.

In the invention described in ( 6 ) above, in the three-dimensional network block, the foamed resin is packed in the three-dimensional network gaps between the resin linear bodies forming the three-dimensional network combination, so that the rigidity is further improved. be able to.

(7) the blades of the process of the invention described in that by producing a three-dimensional mesh-like blocks more resin linear bodies are irregularly entangled, form a blade with a plurality of the three-dimensional mesh-like blocks Can be easily formed.
The blade shape of the three-dimensional mesh block is lightweight and excellent in refraction. By integrally forming the coating layer on this surface, it is possible to form a blade having many voids, and it is possible to obtain a blade that is lightweight and has excellent rigidity.

It is a front view of one embodiment of the present invention. FIG. 2 is an enlarged plan view taken along the line II-II in FIG. 1. FIG. 2 is a left side view of FIG. 1 with a covering layer partially omitted. It is a perspective view of a part of three-dimensional mesh block in the present invention. It is a front view which shows the formation method of a resin linear body . It is a front view which shows the formation method of a three-dimensional mesh block. It is a top view of the shaping die of a three-dimensional mesh block. It is a vertical cross-sectional front view of an inclined part forming die.

The present invention will be described below with reference to the drawings. FIG. 1 is a front view of a rotor blade 1 (hereinafter, simply referred to as a blade), and FIG. 2 is an enlarged plan view crossing II-II line in FIG. FIG. 3 is a left side view of the blade 1 shown in FIG. 1 with a part of the coating layer removed.

As shown in FIG. 1, inclined portions 1B that are inclined toward the longitudinal main axis direction are formed at the upper and lower ends of the vertically long main portion 1A of the rotor blade 1.
An attachment member 1D fixed to the vertical main shaft 11 and fixed to the tip of the horizontal support arm 12 is provided at an arbitrary position on the left side surface 1C (inside surface during rotation).

In FIG. 2, the cross section of the blade 1 with the blade tip facing upward has a center line S connecting the leading edge 1E and the trailing edge 1F as a boundary, and is closer to the right side surface 1G (outer side surface during rotation) than the right side surface 1G. The bulge on the left side 1C (inner side) side is large.

As a result, due to the Coanda effect that occurs during rotation, the velocity of the airflow passing along the inner side surface 1C is higher than that of the airflow passing along the outer side surface 1G, and the airflow passing from the end of the trailing edge 1F to the outside is faster. The rotation efficiency of the blade 1 is increased.

As shown in FIG. 2, FIG. 3 and FIG. 4, a plurality of elastic resin linear bodies 7 are provided with a plurality of three-dimensional net-like blocks 2 by a three -dimensional net-like joined body 3 in which the elastic linear filaments 7 are randomly entangled with each other. The blades 1 are formed by being combined with each other.

The resin linear body 7 has a diameter of about 1 mm to 5 mm, and as shown in FIG. 5, the thermoplastic elastic synthetic resin material melted from the nozzle 6 of the extrusion molding machine 5 can be formed into any shape such as a round shape, a triangular shape, or a plate shape. When the resin linear body 7 hangs down against the pedestal 8 below it, it continuously hangs down and bends irregularly in all directions, and a continuous connecting ring 7A of irregular shape Can be built.

Therefore, when the pedestal 8 is moved downward at a constant speed, the connecting ring 7A is connected for a long time and hardened, so that cutting is performed at a required length. By repeating this, the random line body 7B in which the connecting ring 7A is connected is formed.
A opening it up and down, when passed through the mold, not shown, adjacent to each other by adhesion turbulent line member 7B between, become solid reticulated conjugate 3 having an irregular chain ring, cubic-mesh by this The block 2 is formed.

As the thermoplastic elastic synthetic resin, for example, polyethylene, polypropylene or other thermoplastic synthetic resin is preferably used as a simple substance or a mixture thereof and has a specific gravity of 0.9 to 0.96 and a light weight.

As shown in FIG. 6, a cylindrical molding die 9 having upper and lower through-holes is arranged below a plurality of nozzles 6 of the extrusion molding machine 5, and the resin linear body 7 is hung therein. As shown in FIG. 6, in the forming die 9, there is formed a random body 7B in which connecting rings 7A are connected, and the left and right front and back are adhered to each other, and as shown in FIG. 7, the shape of the forming die 9 is a three-dimensional mesh block. 2 is formed. By moving the pedestal 8 in FIG. 5 downward, a long product can be produced. That is, the shape changes depending on the molding die 9, such as a plate shape, a column shape, or a tubular shape.

In the three-dimensional mesh block 2 of FIG. 4, the nozzle 6 of the extrusion molding machine 5 is arranged in an annular shape, and the resin linear bodies 7 hanging from the nozzle 6 are adhered to each other in the tubular main part molding die 9 and cured. The three-dimensional net-like block 2 having a tubular shape is formed.

Therefore, the main portion 1A of the blade 1 is formed to have a required length. When this molding die is doubled inside and outside and the resin linear body 7 is hung in the inside and outside frames, the tubular three-dimensional mesh block 2 having a uniform thickness can be formed.

As shown in FIG. 2, this molding die 9 is manufactured by manufacturing a plurality of molding dies having a shape in which the blade 1 is divided into a plurality of pieces in the chordal direction, and is formed by the molding dies, and the slender three-dimensional mesh having different thicknesses and shapes. make Jo block 2,2, 2, and juxtaposed so as shown in FIG. 3, joined in the form of blade 1.

As a joining method, for example, an adhesive is used for adhesion, or a burner is used for welding. If necessary, thin plate-shaped ribs may be provided between the adhering surfaces of the adjacent three-dimensional mesh blocks 2 and 2.

FIG. 8 is a vertical cross-sectional front view of an inclined portion forming die for forming the inclined portion 1B with the resin linear body 7. When the resin linear body 7 dripping from the nozzle 6 of the extrusion molding machine 5 in FIG. 5 is dropped into the inclined portion forming die 10 that matches the shape of the inclined portion 1B of the blade 1, the inclined portion forming die 10 Among them, the resin linear body 7 is irregularly bent and adheres to the adjacent resin linear body 7 to form a three-dimensional mesh block (not shown) in the shape of the inclined portion 1B. Cut to length.

A plurality of three-dimensional mesh blocks (not shown) in the shape of the inclined portion 1B are also joined in the chord direction as shown in FIG. 2, like the main portion 1A. After that, the main portion and the inclined portion are joined in the shape of the blade 1. In this case, it is preferable to form a heatable press die, put the three-dimensional mesh block 2 therein, and press-form with the die.

In this case, a cloth impregnated with the surface layer material is put on the inner surface of the mold, the three-dimensional mesh block 2 is placed therein, and the molds are matched and molded. After molding, it is demolded, the surface is adjusted, and the surface agent is used for finishing.

The surface of the blade-shaped three-dimensional mesh-like block 2 (not shown) having the shape of the blade 1 formed in this manner is adhered with cloth (including knitted fabric and non-woven fabric) such as glass fiber cloth and synthetic fiber cloth, and the surface layer The resin is attached to form the coating layer 4. An acrylic resin, a polyurethane resin (mixture) or the like is used as the coating layer resin, but a soft resin is preferable to a hard resin.

As shown in FIG. 2, the mounting member 1D supported on the vertical main shaft 11 and fixed to the tip of the supporting arm 12 is formed by making a hole in the mounting portion of the three-dimensional mesh block 2 and inserting the base end portion into the mounting portion, and then adhering the same. To do. If necessary, the gap can be filled with a resin such as a foamed resin in the three-dimensional mesh-like bonded body 3 at that portion to enhance the rigidity.

In FIG. 2, since each three-dimensional mesh block 2 is formed in a tubular shape , the tube hole can be filled with a foamed resin if necessary. Further, the aggregate may be inserted from the front edge 1E end to the rear edge 1F end.

The three-dimensional mesh block 2 formed in a plate shape or a column shape may be appropriately stacked in a press molding die (not shown) and arranged to form the shape of the blade 1. Further, the wire rods 7B and the three-dimensional net-like combined body 3 can also be formed into the shape of the blade 1 with a forming die.

The three-dimensional mesh block 2 is not limited to the above-mentioned manufacturing method. For example, a bundle of thin resin filaments in a fibrous form is softened and bent in hot air and then placed in the lower mold. There are also methods such as curing and molding.
The blade is not limited to a vertical axis wind turbine blade, but may be a horizontal axis propeller type blade.

INDUSTRIAL APPLICABILITY The present invention has a three-dimensional mesh block as a core and forms a surface layer on the surface, so that it is formed of a resin linear body that is lightweight and elastic like a hollow, has excellent rigidity, and can be used for large wind turbines. It can be used for blades and can be used for efficient power generation.

1. Rotor blade 1A. Main part 1B. Inclined portion 1C. Left side 1D. Mounting member 1E. Leading edge 1F. Trailing edge 1G. Right side 2. Three-dimensional mesh block 3. Three-dimensional mesh-like bonded body 4. Coating layer 5. Extruder 6. Nozzle 7. Resin linear body 7A. Link 7B. Random body 8. Stand 9. Main part mold
Ten. Inclined mold
11. Vertical spindle
12. Support arm S. Center line

Claims (7)

A lift type blade of a wind turbine, for each block-shaped mold in which the blade is divided into a plurality of blocks, the resin linear body extruded from a plurality of nozzles is lowered, and a plurality of resin linear bodies are used in the lowering process. Is a three-dimensional mesh block in which an infinite number of irregular voids are formed by forming innumerable continuous irregular loop-shaped portions in the longitudinal direction, and adhering the loop-shaped portions to each other in the mold frame. A rotor blade , which is formed by combining a plurality of the three-dimensional net-like blocks into a blade shape, adhering and integrating them, and covering the entire surface with a coating layer . In the three-dimensional mesh block, a single wire of a plurality of resin linear members forms irregular connecting rings in all directions in the mold and is adhesively cured adjacent to each other to form an inner mold of the mold. the rotor blade according to claim 1, characterized in that is has. The three-dimensional mesh-like blocks, rotor blade according to claim 1 or 2 things Horizontal, characterized Rukoto coupled together by a plurality parallel chordal the blade shape. 4. The rotor blade according to claim 3, wherein the core material of the three-dimensional mesh block is a tubular body oriented in the vertical direction, and a plurality of core materials are combined in the chord direction and bonded in a blade shape . The three-dimensional mesh-like blocks with each other, the rotor blade according to any one of claims 1 to 4 in the adhesive facing surface by interposing thin plate-like rib which is characterized that you adhere to the blade shape and the adjacent one another. The rotor blade according to any one of claims 1 to 5, wherein in the three-dimensional mesh block, a foamed resin is filled in a three-dimensional mesh gap between resin linear bodies forming the three-dimensional mesh block. .. In the production method of the lift type blade of a wind turbine, a blade-shaped mold is divided into a plurality of blocks to form a block-shaped mold, and for each of the molds, a resin linear body extruded from a plurality of nozzles is lowered and lowered. In the process, a plurality of resin linear bodies form an infinite number of continuous irregular loop-shaped portions in the longitudinal direction, and by adhering the loop-shaped portions to each other in the mold, innumerable irregular voids are formed. A method for manufacturing a rotor blade, comprising forming a formed three-dimensional mesh block, combining a plurality of the three-dimensional mesh blocks into a blade shape and integrating them, and applying a coating layer to the entire surface thereof .

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