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CN106715097A - 具有安全边缘的复合部件 - Google Patents

具有安全边缘的复合部件 Download PDF

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Publication number
CN106715097A
CN106715097A CN201580049586.3A CN201580049586A CN106715097A CN 106715097 A CN106715097 A CN 106715097A CN 201580049586 A CN201580049586 A CN 201580049586A CN 106715097 A CN106715097 A CN 106715097A
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CN
China
Prior art keywords
sapwood
resin
laminate
composite part
edge
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201580049586.3A
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English (en)
Inventor
S·桑德考克
S·瓦尔德洛佩尔
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Vestas Wind Systems AS
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Vestas Wind Systems AS
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Publication date
Application filed by Vestas Wind Systems AS filed Critical Vestas Wind Systems AS
Publication of CN106715097A publication Critical patent/CN106715097A/zh
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/028—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/302—Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
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    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
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    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
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    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/065—Rotors characterised by their construction elements
    • F03D1/0675—Rotors characterised by their construction elements of the blades
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    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Sustainable Energy (AREA)
  • Combustion & Propulsion (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Sustainable Development (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Wind Motors (AREA)

Abstract

描述了一种用于风轮机叶片的诸如抗剪腹板之类的复合部件(130)。所述部件包括模制的层压件(44)，此层压件由借助树脂整合的一个或多个纤维层(40)形成并且限定层压件边缘(48)。边材条(60)邻近所述层压件边缘(48)定位并且与所述层压件整合。在具体实施例中，所述边材(60)由闭孔泡沫制成。因此，在模制过程中树脂不渗透到所述边材(60)的本体中。在模制过程之后，所述边材(60)的一部分(60a)被移除以显露所述边材的基本无树脂的暴露表面，该暴露表面限定所述部件的安全边缘(64)。

Description

具有安全边缘的复合部件
技术领域
本发明涉及具有安全边缘以便于搬运的复合部件，并且涉及制造这种部件的方法。本发明特别应用于风轮机叶片的制造中使用的复合部件。
背景技术
图1在立体图中示出了现有技术的风轮机叶片10。风轮机叶片10从大体圆柱形的根部11纵向延伸至末端13。在使用中，叶片10的根端11附接至风轮机(未示出)的轮毂。在剖面中，叶片10从根部11处的圆形轮廓过渡至叶片10的最宽部分处的机翼轮廓，此最宽部分称作“肩”15。在肩15与末端13之间，叶片具有这样的机翼轮廓，该机翼轮廓的厚度与翼弦朝着末端13稳定地减小。
图2示出了叶片10的剖面，并且显示出：叶片10包括外壳12，此外壳由背风壳14与迎风壳16制得。壳14、16是由玻璃纤维加强塑料(GRP)模制成。外壳12的一部分是夹层板构造，并且这部分外壳包括轻质泡沫芯(例如聚氨酯)18，此芯夹在内GRP层(蒙皮)20与外GRP层(蒙皮)22之间。
叶片10包括第一对翼梁帽24、26以及第二对翼梁帽28、30，各对翼梁帽布置在外壳12的夹层板区域之间。每对中的一个翼梁帽24、28与迎风壳16整合在一起并且每对中的另一个翼梁帽26、30与背风壳14整合在一起。各对中的翼梁帽相互对立并且沿叶片10的长度纵向延伸。
第一纵向延伸的抗剪腹板32桥接第一对翼梁帽24、26，并且第二纵向延伸的抗剪腹板34桥接第二对翼梁帽28、30。与翼梁帽24、26、28、30结合的抗剪腹板32、34形成一对I形梁结构，这一对I形梁结构将负载从旋转的叶片10有效地传递至风轮机(未示出)的轮毂。翼梁帽24、26、28、30特别传递伸缩弯曲负载，而抗剪腹板32、34传递叶片10中的剪切应力。
抗剪腹板32、34在真空辅助树脂传递模制过程(VARTM)中制成。图3中示出了此过程，该图仅示出了腹板的底部。玻璃纤维织物层40铺叠在模具50的表面上。这些层的边缘42对准以限定抗剪腹板32、34的边缘43。层40被真空袋46包绕以限定围绕层40的密封区域。然后，借助真空泵从袋46排除空气，并且将树脂引入到袋46中。将树脂灌注在玻璃纤维层40之间并且灌注到玻璃纤维层40中。然后，加热模具50以固化树脂，一旦树脂固化，就将部件脱模。
产生的抗剪腹板32、34具有边缘43，此边缘由玻璃纤维层40的对准的边缘42以及那些边缘42的区域中的固化树脂限定。当层40铺在模具50上时难以精确对准边缘42，因而边缘43易于不平。而且，灌注树脂后，抗剪腹板32、34的边缘43处往往存在量不均衡的过多树脂。这样的结果是：在树脂固化后，抗剪腹板32、34的边缘43往往粗糙，边缘43处的坚硬固化树脂形成锯齿状。粗糙边缘43因此可能会存在使抗剪腹板32、34难以搬运并且搬运可能不太安全的安全隐患。
有潜在危险的粗糙边缘43可以在制成后通过修剪部件的边缘而移除。然而，固化树脂非常坚硬，因此需要金刚石切割锯来切断部件以修剪边缘，使得修剪操作是昂贵且耗费时间的过程。
可以在固化过程之前当折叠玻璃纤维层40铺在模具50中时通过折叠玻璃纤维层40的边缘而整理边缘43，然而这仅部分地缓解了问题，并且实际上仍需要制成后的修剪操作。还可以通过给模具提供呈金属杆或者金属条的形式的抵接件并且抵靠抵接件铺玻璃纤维层40而整理边缘43。当部件脱模时，产生的边缘更齐整。然而，即使在此情况下仍保持一定程度的粗糙度，并且使部件脱模的动作往往留下树脂的断面区，此断面区呈现锋利并且有危险的边缘。
发明内容
以此为背景，本发明涉及一种制作用于风轮机叶片的复合部件的方法，所述复合部件具有安全边缘，并且所述方法包括：在模具中布置一个或多个纤维层使得所述纤维层限定层压件边缘；邻近所述层压件边缘布置边材；借助树脂整合所述纤维层与所述边材；基本防止所述树脂渗透到所述边材中；以及移除所述边材的一部分以显露所述边材的限定所述复合部件的安全边缘的基本无树脂的暴露表面。
本发明的方法提供这样一种简单而有效的手段，该手段用于在不需要制造成部件之后的漫长并且昂贵的处理的情况下提供用于风轮机叶片的复合部件上的对手安全的边缘。边材在制造过程中整合到部件中，并且通过移除边材的一部分而容易地提供边材的基本无树脂的暴露表面。因为树脂不被允许渗透到边材中，所以边材的芯无硬化树脂，并且边材的一部分能因此被快速而容易地移除而无需精心设计的工具。
移除所述边材的一部分的步骤可以包括：沿与所述层压件边缘间隔开的割裂线割裂所述边材；并且移除所述边材的位于所述割裂线外侧的牺牲部分，使得所述边材的位于所述割裂线内侧的保护部分保持与所述层压件整合，并且所述保护部分包括限定所述部件的所述安全边缘的所述基本无树脂的暴露表面。在割裂线处割裂边材的操作提供移除部分边材的特别简单的方法。割裂过程能由手执行，例如利用手持切割工具，或者割裂过程可以是机械化的。
所述边材可以由基本不渗透树脂的材料制成，使得基本避免所述树脂渗透到所述边材中。利用基本不渗透树脂的材料尤其有益，因为这意味着无需防止树脂渗透到边材中的额外措施。
所述方法还可以包括在所述模具中上下叠置地布置多个纤维层，从而形成所述层压件。
所述方法可以包括使所述边材以可移除的方式固定至所述模具。以此方式，所述边材能够固定就位以限定安全边界，并且在铺放时纤维层能够抵靠边材牢固地叠放而不会将边材移出其正确位置。而且，使边材以可移除的方式固定至模具意味着当施加真空时或者在树脂灌注或者固化过程中边材不移离其正确位置。当形成过程完成时，边材能随着部件脱模而从模具脱开。
所述方法可以包括在所述模具上布置剥离片层，并且将所述纤维层与所述边材布置在所述剥离片层上方。以此方式，在完成的部件中，剥离片层设置在部件的下表面上并且在纤维层与边材这两者上方延伸。剥离片层能随后被移除以在纤维层与边材这两者上提供粗糙不平的表面。
此外或者另选地，所述方法可以包括在所述纤维层与所述边材上方布置所述剥离片层，从而在部件的上表面上设置剥离片层，此剥离片层在纤维层与边材这两者上方延伸。
所述边材的初始厚度可以等于或者大于所述纤维层的初始结合厚度，并且所述方法还可以包括在真空辅助模制过程中压缩所述纤维层与所述边材，使得所述边材的最终厚度与所述纤维层的最终结合厚度基本相同。以此方式，纤维层与边材这两者可以压缩至基本相同的厚度，从而提供经过纤维层并且到达边材的连续的上表面。
所述方法还可以包括将液体树脂供应至所述模具。另选或者另外，纤维层可以预浸渍有树脂。所述方法还可以包括通过使所述树脂固化而整合所述纤维层与所述边材。
本发明延及一种根据以上所述的本发明的方法制成的复合部件，并且延及一种根据上述本发明的方法制成的抗剪腹板。本发明还延及一种包括抗剪腹板的风轮机叶片，并延及一种包括这样的风轮机叶片的风轮机。
本发明还延及一种用于风轮机叶片的复合部件，此复合部件包括：由树脂以及一个或多个纤维层形成的层压件，所述层压件具有由所述一个或多个纤维层的边缘限定的层压件边缘；以及邻近所述层压件边缘定位并且借助所述树脂与所述层压件整合的边材。所述边材具有基本无树脂的暴露表面，所述暴露表面限定所述复合部件的安全边缘。
所述边材用作保护纤维层的边缘的缓冲器，否则纤维层的边缘将形成锋利的有锯齿的边缘。以此方式，层压部件的边缘是边材的基本无树脂的暴露表面，而不是纤维层的有锯齿的边缘。
因为边材的表露表面基本是无树脂的，所以暴露表面没有过多树脂，否则这些过多树脂会形成不平的、锋利的边缘并且对搬运复合部件的人员造成安全危害。因此，部件的边缘基本不存在坚硬树脂提供了对手安全的边缘，此对手安全的边缘使得部件对于搬运相当安全。
因此，借助边材的基本无树脂的暴露表面，本发明在无需制造成部件之后的漫长而昂贵的处理过程的情况下提供用于风轮机叶片的复合部件上的对手安全的边缘。
所述边材可以由基本不渗透树脂的材料制成。以此方式，边材的内芯在部件的制造过程中保持基本无固化树脂，从而使得边材相当容易地被切割以显露暴露表面。例如，所述边材可以包括泡沫、巴尔沙木以及/或者聚苯乙烯，并且/或者可以由闭孔泡沫制成以避免树脂渗透。
所述边材可以呈条的形式。以此方式，边材能沿部件的边缘的长度延伸，并且能弯曲成适应边缘的形状。如果需要，多个条能够首尾相接放置以覆盖边缘的全长。
所述边材可以由可压缩材料制成。这在复合形成过程中涉及真空阶段时尤其有益。当复合部件的纤维层放置在真空条件下时，纤维层被压缩。边材的压缩性意味着当施加真空时边材也被压缩，从而匹配层压层的压缩，因而提供穿过层压件以及边材的连续表面。
在边材由可压缩材料制成的实施方式中，在完成的复合部件中，边材可以处于压缩状态。
所述复合部件可以包括布置在所述层压件与所述边材上方的剥离片层。剥离片层可以被移除以显露位于层压件与边材两者上的粗糙不平的表面，从而便于层压件与边材粘合至另一表面。
所述复合部件的所述安全边缘可以通过沿割裂线割裂所述边材并且移除所述边材的位于所述割裂线外侧的牺牲部分以显露所述边材的所述基本无树脂的暴露表面而形成。以此方式，基本无树脂的暴露表面能够在无需精心设计的工具的情况下快速而容易地形成。
所述部件可以由VARTM形成。
所述部件可以是抗剪腹板。另选地，所述复合部件可以是用于风轮机的诸如隔板、凸缘或者平台之类的另一部件。
本发明还延及一种包括根据以上所述本发明的复合部件的风轮机叶片，并且延及一种包括这样的风轮机叶片的风轮机。
为了避免疑问，用在本文中时术语“层压件”意图涵盖由一个或多个层制成的零件，并因此在本发明范围内包括由单个层制成的零件。
附图说明
上文已经作为本发明的背景描述了图1与图2以及图3，图1与图2分别以立体图与剖面图示出了风轮机叶片，并且图3示出了制作抗剪腹板的方法。为了能够更容易理解本发明，现在将仅以非限制性实施例方式参照下面的附图描述本发明的具体实施方式，在附图中：
图4是根据本发明的一个实施方式的复合部件的示意性局部立体图；
图5A至图5I示出了制作图4的复合部件的方法中的阶段；
图6A与图6B分别是由图5A至图5I的方法制作复合部件的立体图与局部放大剖面图；以及
图7是结合有图6的复合部件的风轮机叶片的剖面图。
具体实施方式
图4示出了用于风轮机叶片的复合部件130。在此实施例中，复合部件130是抗剪腹板，并且图4仅示出了抗剪腹板的底部。复合部件130包括由多个层压层40(例如玻璃纤维织物层)形成的层压件44，层压层40由固化树脂整合在一起。层压层40的边缘42限定层压件边缘48。一条泡沫60在层压件边缘48旁边延伸并且借助固化树脂与层压件44整合。如稍后将更详细描述的，此条泡沫60限定抗剪腹板130的对手安全的边缘，从而使得抗剪腹板130能够在使用中被安全搬运。
现在将参照图5A至图5I描述制作抗剪腹板130的方法。
首先参照图5A，提供模具50以制作抗剪腹板130，此模具具有模具表面51，此模具表面的形状对应待形成在模具50中的抗剪腹板130的外部轮廓。将离型膜(未示出)施加在模具50的表面51上。接着，如图5B中所示，将第一或者下剥离片层52布置在模具50中，位于离型膜上方。
如图5C中所示，将层压层40(这里例示成剥离纤维织物)铺在剥离片层52上方。尽管此实施例中仅示出了剥离纤维层，但是要理解，层压件44可以包括其他层或者部件，例如抗剪腹板130可以是夹层板构造，在此情况下，诸如泡沫或者巴尔杉木之类的芯材可以设置在纤维层40之间。纤维层40的边缘42在模具50中对准，并且一旦对准就可视情况修剪。层40的边缘42限定层压件边缘48。
如图5D中所示，将边材60布置在模具50中，位于层压件边缘48的旁边。边材60由不渗透树脂的材料(优选可压缩材料)适当形成。在此实施例中，边材60是由膨胀的氯丁橡胶或者硅树脂制成的一条闭孔泡沫。泡沫的闭孔在随后的树脂灌注过程中基本防止树脂灌注到边材条60的本体中。
边材60具有大约5mm与大约10mm之间的宽度w以及大约3mm与大约8mm之间的厚度t。在真空袋成型过程中边材60优选在与层压件共固化之前至少与层压件44一样厚。优选地，边材60在共固化之前比层压件44略厚。如稍后将描述的，边材60的压缩性使得边材60能够在共固化过程中与层压件44协调地被压缩，使得边材60最终在完成的部件中的厚度与共固化的层压件44的厚度相同。
仍参照图5D，边材条60的底侧预涂覆有粘合剂层，并且覆盖有可剥离的保护层(未示出)。在条60安置在模具50上之前，移除保护层以暴露粘合剂层。边材60铺在层压件边缘48旁边，底侧62向下面朝模具50，使得边材60经由剥离片层52固定至模具50以在随后的处理步骤中将边材60保持就位。
接着，如图5E中所示，将第二或者上剥离片层54铺在层压件44与边材60上方。然后，将真空通道70在边材60的外侧铺在剥离片层54的顶上，并且将剥离片层54绕真空通道70折叠。真空通道70稍后将用于使空气从模具50中的部件排出。
参照图5F，一旦真空通道就位，就将一层离型膜56铺在层压件44上，并且将便于树脂灌注的一层转移网58铺在离型膜56上。
现在参照图5G，一旦所有部件都已经铺叠在模具50中，这些部件就由真空袋72覆盖。利用丁基橡胶密封带74将真空袋72密封至模具50以绕部件创建密封区域。
然后，空气经由真空通道70从密封区域被排出。当空气排出时，真空袋72的内部与外部之间的压力差使真空袋倚靠并压缩纤维层40。如先前提及的，边材60在真空压力下也是可压缩的，并且边材60在空气从密封区域被移除时与纤维层40一起被压缩。在此共固化过程中，边材60被压缩成其厚度相当于压缩后的层压件44的厚度。
在达到所需真空水平之后，将树脂引入到密封区域中。树脂灌注到纤维层40中并且灌注在纤维层40之间以及层压件边缘48与边材60之间。因为边材60基本是不渗透树脂的，所以树脂不明显灌注到边材60的本体或者“芯”中。因此，边材60的芯保持基本无树脂。
然后，通过加热使树脂固化。当树脂固化时，边材60与层压件44整合，并且沿层压件边缘48结合至层压件44。
一旦树脂固化就使抗剪腹板130脱模：移除真空袋72；剥离离型膜56以及转移网58；从模具50移除抗剪腹板130并且修剪剥离片层52、54(如图5H中所示)。
参照图5I，此图示出了该过程的最后阶段。为了阐明之目的，图5I中示出了边材60的完整轮廓，但是要理解，实际上边材60的上表面会被上剥离片层54覆盖，因此将不可见。
在最后阶段中，边材60沿割裂线62被割裂。割裂线62与层压件边缘48间隔开距离d，此距离在大约2mm与大约5mm之间。以此方式，将边材60的位于割裂线62外侧的割裂部分60a从部件130移除，并且边材60的位于割裂线62内侧的保护部分60b保持与层压件44整合。
模制过程之后，用固化树脂薄层覆盖边材60的外侧。然而，闭孔泡沫的不渗透的性质意味着边材60的本体/芯基本不存在树脂。因此，当边材60沿割裂线62被割裂时，保护部60b的洁净(即，无树脂)表面64(参见图6A)暴露，此表面限定抗剪腹板130的对手安全的边缘64。此边缘64基本不存在坚硬的树脂，这使得该边缘对搬运来说相对安全。边材60的芯不存在树脂也有利地使边材60相对容易切割。例如，边材60能够容易由手利用刀切割，这特别方便。
一旦完成割裂过程，无需进一步处理抗剪腹板130以容许安全搬运。这避免了对费时、劳动密集的加工过程的需要，必需采用费时、劳动密集的加工过程以最后加工由传统方法制成的复合部件的边缘。
图6A与图6B示出了完成的抗剪腹板130。保护部60b借助固化树脂与层压件44整合，并且保护层压件边缘48，从而创建对手安全的边缘64。如图6B中最佳所示，作为共固化过程的结果，保护部60b处于压缩状态，在此状态中该保护部的厚度t基本等于共固化的层压件44的厚度。
剥离片层52、54在抗剪腹板130的层压件44与保护部60b两者上延伸。当抗剪腹板130结合到风轮机叶片110中时，剥离片层52、54被移除以在层压件44与保护部60b两者上留下粗糙不平的键合表面。粘合剂施加至此键合表面以便使抗剪腹板130粘合至翼梁帽24、26、28、30(参见图7)，表面的粗糙度用于提高附着力。
除搬运益处之外，保护部60b的存在不明显影响抗剪腹板130的物理性能。如图6B中最清楚地看到的，保护部60b借助固化树脂与层压件44牢固地整合，并且保护部60b以与层压件44相同的方式设置有剥离片层52、54，这意味着保护部60b的表面能牢固粘附至风轮机叶片110。
如图7中所示，当抗剪腹板130结合到风轮机叶片110中时，抗剪腹板130完全布置在叶片110的内部中。因此，抗剪腹板130的边缘64不可见。因此，在完成的风轮机叶片110中，边缘64的外观不重要。
尽管本实施方式中描述的复合部件是抗剪腹板，但是在其他实施方式中复合部件可以例如是隔板、凸缘或者平台。
边材无需由泡沫材料制成，而可以由任一适当的材料制成，适当材料的实施例包括纤维材料、蜂巢结构、橡胶、巴尔杉木以及聚苯乙烯。边材无需借助粘合剂层粘附至模具，而是可以借助任何适当的机构固定就位，或者可以简单地平放在模具上而不固定就位。
如果需要可以省略任何或者所有的剥离片层、离型膜以及/或者转移网。另外的部件可以在真空袋布置就位之前也铺叠在模具中。
尽管本方法中描述的纤维层是干纤维层并且在树脂灌注过程中树脂灌注到这些层中，但是纤维层可以是预浸渍层，这些预浸渍层在布置在模具中之前浸渍有树脂。在此情况下，可以省略树脂灌注步骤。
在描述的实施例中，边材用手利用刀被割裂。然而，边材可以借助任何适当机构(例如锯或者激光)被割裂。无论如何，割裂过程可以是人工的或者自动的。尽管无需在割裂过程之后为了提供对手安全的边缘而随后加工，但是如果期望可以采用进一步加工与精加工阶段。
在其他实施方式中，代替割裂，可以研磨或者用砂纸磨边材以显露基本无树脂的暴露表面。
尽管边材优选由基本不渗透树脂的材料制成，但是在其他实施例中可以以其他方式防止树脂渗透到边材的本体中。例如，边材可以封装在诸如塑料膜之类的不渗透树脂的膜内。在这些情况下，边材的本体无需必定由不渗透树脂的材料制成。
因此，本发明不限于以上所述的示例性实施方式，对本领域的普通技术人员而言，不脱离本发明的如由所附权利要求限定的范围的情况下的一些其他变更例或者变型例会是显而易见的。

Claims (27)

1.一种制作用于风轮机叶片的复合部件的方法，所述复合部件具有安全边缘，并且所述方法包括：
将一个或多个纤维层布置在模具中，使得所述纤维层限定层压件边缘；
邻近所述层压件边缘布置边材；
借助树脂整合所述纤维层与所述边材；
基本防止所述树脂渗透到所述边材中；以及
移除所述边材的一部分以显露所述边材的基本无树脂的暴露表面，该基本无树脂的暴露表面限定所述复合部件的安全边缘。
2.根据权利要求2所述的方法，其中，移除所述边材的一部分的步骤包括：
沿与所述层压件边缘间隔开的割裂线割裂所述边材；以及
移除所述边材的位于所述割裂线外侧的牺牲部分，使得所述边材的位于所述割裂线内侧的保护部分保持与所述层压件整合，并且所述保护部分包括限定所述复合部件的所述安全边缘的所述基本无树脂的暴露表面。
3.根据权利要求1或者权利要求2所述的方法，其中，所述边材由基本不渗透树脂的材料制成，使得基本防止所述树脂渗透到所述边材中。
4.根据权利要求1至3中任一项所述的方法，所述方法还包括在所述模具中上下叠置地布置多个纤维层，从而形成所述层压件。
5.根据权利要求1至4中任一项所述的方法，所述方法包括将所述边材以可移除的方式固定至所述模具。
6.根据权利要求1至5中任一项所述的方法，所述方法包括在所述模具上布置剥离片层，并且将所述纤维层与所述边材布置在所述剥离片层上方。
7.根据权利要求1至6中任一项所述的方法，所述方法包括在所述纤维层与所述边材上方布置剥离片层。
8.根据权利要求1至7中任一项所述的方法，其中，所述边材的初始厚度等于或者大于所述纤维层的初始结合厚度，并且所述方法还包括在真空辅助模制过程中压缩所述纤维层与所述边材，使得所述边材的最终厚度与所述纤维层的最终结合厚度基本相同。
9.根据权利要求1至8中任一项所述的方法，所述方法还包括将液体树脂供应至所述模具。
10.根据权利要求1至9中任一项所述的方法，所述方法还包括通过使所述树脂固化而整合所述纤维层与所述边材。
11.一种根据权利要求1至10中任一项所述的方法制成的复合部件。
12.一种根据权利要求1至20中任一项所述的方法制成的抗剪腹板。
13.一种包括权利要求12所述的抗剪腹板的风轮机叶片。
14.一种包括权利要求13所述的风轮机叶片的风轮机。
15.一种用于风轮机叶片的复合部件，该复合部件包括：
由树脂以及一个或多个纤维层形成的层压件，所述层压件具有由所述一个或多个纤维层的边缘限定的层压件边缘；以及
邻近所述层压件边缘定位并且借助所述树脂与所述层压件整合的边材；
其中，所述边材具有基本无树脂的暴露表面，所述基本无树脂的暴露表面限定所述复合部件的安全边缘。
16.根据权利要求15所述的复合部件，其中，所述边材由基本不渗透树脂的材料制成。
17.根据权利要求15或者权利要求16所述的复合部件，其中，所述边材包括泡沫、巴尔沙木以及/或者聚苯乙烯。
18.根据权利要求17所述的复合部件，其中，所述边材由闭孔泡沫制成。
19.根据权利要求15至18中任一项所述的复合部件，其中，所述边材呈条的形式。
20.根据权利要求15至19中任一项所述的复合部件，其中，所述边材由可压缩材料制成。
21.根据权利要求20所述的复合部件，其中，所述边材处于压缩状态。
22.根据权利要求15至21中任一项所述的复合部件，所述复合部还包括布置在所述层压件与所述边材上方的剥离片层。
23.根据权利要求15至22中任一项所述的复合部件，其中，所述复合部件的所述安全边缘通过沿割裂线割裂所述边材并且移除所述边材的位于所述割裂线外侧的牺牲部分以显露所述边材的所述基本无树脂的暴露表面而形成。
24.根据权利要求15至23中任一项所述的复合部件，其中，所述复合部件由VARTM形成。
25.根据权利要求15至24中任一项所述的复合部件，其中，所述复合部件是抗剪腹板。
26.一种包括权利要求15至25中任一项所述的复合部件的风轮机叶片。
27.一种包括权利要求26所述的风轮机叶片的风轮机。
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