CN1034642C - 制造风扇叶片的方法 - Google Patents

制造风扇叶片的方法 Download PDF

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CN1034642C
CN1034642C CN91103683A CN91103683A CN1034642C CN 1034642 C CN1034642 C CN 1034642C CN 91103683 A CN91103683 A CN 91103683A CN 91103683 A CN91103683 A CN 91103683A CN 1034642 C CN1034642 C CN 1034642C
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preform
fan blade
mould
flexible pouch
glass
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CN1058168A (zh
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罗伯特·C·蒙罗
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Hudson Products Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • B29D99/0028—Producing blades or the like, e.g. blades for turbines, propellers, or wings hollow blades
    • 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
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
    • 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
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/446—Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
    • 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
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/541—Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/3642—Bags, bleeder sheets or cauls for isostatic pressing
    • B29C2043/3649—Inflatable bladders using gas or fluid and related details
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/10—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/10—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
    • B29C43/12—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies using bags surrounding the moulding material or using membranes contacting the moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers

Abstract

一种模制空心风扇叶片的方法和装置，其中，采用一个玻璃纤维预型件支承模子中的玻璃纤维布的上层。当树脂注入模子时，使玻璃纤维布和玻璃纤维预型件被浸透，由此，在模制期间将二者粘合在一起成为一个单一的元件，在这期间要加热和加压。

Description

制造风扇叶片的方法
本发明涉及制造玻璃纤维风扇叶片的方法，更具体地说，是涉及使用玻璃纤维预型件制造空心单件风扇叶片的方法。
有很多制造风扇叶片的技术，所用的方法依赖于制成的叶片是空心的还是实心的，是单件的还是由多件固定在一起的。所用的方法也依赖于所需的翼面形状，简单的形状适于压制，较复杂的形状则要求模制或敷层工艺。本发明涉及外形较复杂的空心、单件玻璃纤维风扇叶片的结构，它采用了树脂转移或喷射模制法。在操作期间，不需要内翼梁或充填物来提供附加的弯曲强度，与具有嵌入模内的翼梁的叶片相比较，它的空心的轻的结构能提供一种运转更安全的叶片。
在过去，这样的空心的风扇叶片被制成两件。第一件包括翼型，而第二件包括用于将翼面连接到转轴或轮毂上的叶柄。在一些例子中(U.S.4,345,877，R.C.Monroe)，翼面和叶柄由不同的材料制造，在另外的例子中(U.S.4,720,244，Kloppel et al)，其部件由玻璃纤维制造，然后被粘结或铆接在一起。
后来，所有的玻璃纤维叶片是绕一个在模子中的柔性袋缠绕多层玻璃纤维布层，再向袋内充气，然后将树脂压入模子，以致浸透玻璃纤维布而制成的。然后，使风扇叶片固化，并将柔性袋取出。为了使树脂更均匀地分布(以避免出现树脂加厚或浓稠部分，这可能导致破裂)，并避免玻璃纤维出现褶皱，在柔性袋中装有“摊铺器”或硬模，它们在该处扩张以进一步支承玻璃纤维布。在模制期间，摊铺器用于玻璃纤维叶柄或连接端中，以及翼面端中。在叶片和叶柄组装之前，先插入，再取下摊铺器是很费力的，并限制了风扇叶片颈部的最小尺寸和形状。虽然摊铺器大大提高了产品质量，但是因为必须将其从部件内取出，所以需要将叶片制成两件。
制造空心的单件风扇叶片的典型方法涉及在加压的柔性袋中采用粗制的纸板模型。这就必然导致风扇叶片的不均匀的壁厚。另外，因为当树脂经颈部注入时，模子中的玻璃纤维布会移动，所以，用纸板模型制造出的风扇叶片的玻璃纤维层上有许多褶皱，并有裂开的树脂浓稠区域。在大多数普通例子中，在注入树脂之前，纸板不能精确地固定玻璃纤维层并使其定位。
本发明的目的是克服上述缺点，提供一种制造空心的单件风扇叶片的方法，它与以前制造这种风扇叶片的方法相比，更省力，制出的叶片更结实，看上去更美观，所以次品率也较低。本发明的另一个目的是提供一种方法，它尤其能减少树脂浓稠区域的出现，同时也对玻璃纤维布提供支承和精确的布置和固位，以致当将树脂压入模子时，能减少其出现褶皱和移动。通过下面进一步的描述，对本发明的上述和其他目的将会更清楚。
本发明提供了一种制造空心风扇叶片的方法，它包括下述步骤：在模子的下部铺设玻璃纤维布或其他种类的纤维，在模子中的玻璃纤维布上放置一个柔性袋，在该柔性袋顶部没置一个玻璃纤维预型件，用另外的玻璃纤维布复盖预型件，将模子闭合，将柔性袋充气，将树脂注入模子使之处于柔性袋周围，并浸透玻璃纤维布和玻璃纤维预型件，由此，在该组合体的模制和固化期间，将二者粘结在一起形成一个单一元件。
图1是一个已制成的风扇叶片的部分剖视图；
图2是玻璃纤维预型件的视图；
图3是沿图2中3-3线的剖视图；
图4是沿图2中4-4线的剖视图；
图5是沿图2中5-5线的剖视图；
图6是铺设操作图；
图7是封闭了预型件和柔性袋的模子的视图；
图8是固化作业期间模子的视图；
首先参照图1，其中示出了空心的风扇叶片10，它具有一颈部12和一个翼面部分14。颈部12有一个凸缘16，用于与一个转轴或轮毂(未显示)相连。翼面部分14的形状根据工作条件的需要而定，但在任何情况下，其中空结构都是由多层玻璃纤维构成的。不需要有金属内翼梁来提供安全运转所需的足够强度。
图2示出了用于风扇叶片10结构中的预型件18，事实上，预型件18最后要成为风扇叶片10的一部分。预型件18的曲率可根据需要变化，其典型的曲率示于图3，图4和图5中。正如可以想到的那样，预型件18是仅用于支承模子中玻璃纤维布的上层，直至它们被浸透树脂和固化。玻璃纤维布的下层将由模子的下半部支承。所以，风扇叶片10的整个形状不需要由预型件18支承，而仅是其上半部需要支承。
预型件18最好是由铺在所需曲面型芯上的根据需要吹制成形的碎玻璃纤维丝，或玻璃纤维织物构成的。在达到所需厚度之后，用少量树脂粘合剂浸透碎玻璃纤维或织物，并将其混合物在加热室固化，使其被固定在一起，形成一个所需的半硬的预型件18。用于固定预型件18的少量树脂粘合剂与风扇叶片10的模制期间所用的树脂是相容的。在预型件18固化之后，将其型芯取下，它就可在模子中用于支承玻璃纤维布的上层，以形成风扇叶片10。所以，预型件18的结构应与制成的叶片形状一致，以便进行玻璃纤维的精确布置。
现在参照附图6～8，图中显示了模制风扇叶片10的步骤。首先，将不同层数的玻璃纤维布24或其他种类的玻璃纤维铺在模子22的下半模20上，在其上面放置一个模子闭合后可向其中加压的柔性袋26。然而，当柔性袋还是瘪的时，将预型件18放在其上面，以便能支承绕预型件折叠的和/或放在其顶部的玻璃纤维布的上层。因为预型件18能维持铺设在模子22中的干玻璃纤维布24，并使其精确定位，所以，在模子22中出现褶皱和/或出现树脂浓稠区域的可能性如果不是完全消除了的话，也是大大减少了。
在模子22闭合并夹紧之后，通过颈部12向柔性袋26充气，然后使其密封，由此，将干玻璃纤维布24在模子22中限制在位，在所述适当充气的条件下，将树脂通过颈部12泵入或注入模子22中，使预型件18和玻璃纤维布层24浸透，由此将二者粘合在一起。然后将该混合物加热使其固化。然后将模子22打开，使新成形的风扇叶片10脱模之后，再取出柔性袋26。
预型件18的使用能使玻璃纤维布24在模子22闭合后保持其最佳位置。另外，可将预型件18制成任何平面形状，以及直的或锥形形状，并能容易地与一个锥形连接端(颈部12)相适应，该连接端末端通常是一个便于安装的圆柱形紧固部分。采用上述的模制树脂转移法或树脂注入法，可制造具有更好的空气动力性的，更结实和更美观的单件风扇叶片。

Claims (9)

1.一种制造空心风扇叶片的方法，包括下述步骤：
a.将玻璃纤维布铺在模子的下部；
b.将一个柔性袋放在所述模子中的玻璃纤维布上面；
c.将一个与所述叶片内侧形状相一致的半硬玻璃纤维预型件放入所述柔性袋的顶部；
d.用所述玻璃纤维布复盖所述预型件；
e.将模子闭合，并向所述柔性袋中充气；
f.向所述模子中注入树脂使之处于所述柔性袋的周围，使所述玻璃纤维布和预型件都被浸透，由此在模制期间将二者粘结在一起成为一个单一的元件；
g.使所述风扇叶片固化，将所述柔性袋放气，从所述模子中取出风扇叶片。
2.如权利要求1所述的方法，其特征在于：包括构成所述玻璃纤维预型件的步骤，它是由与所述叶片树脂相容的适当的树脂粘合剂固定在一起的。
3.如权利要求2所述的方法，其特征在于：所述预型件是由碎的玻璃纤维构成的。
4.如权利要求2所述的方法，其特征在于：所述预型件是由玻璃纤维织物构成的。
5.如权利要求2所述的方法，其特征在于：所述风扇叶片为空心的单件结构，它包括一个颈部和一个翼面部分。
6.模制空心风扇叶片的方法，包括下述步骤，将玻璃纤维材料支承在模子中一柔性袋上的一玻璃纤维预型件上，在模制期间，预型件与所述材料粘合，由此，形成一个风扇叶片的整体部件。
7.如权利要求6所述的方法，其特征在于：还包括构成所述玻璃纤维预型件的步骤，它是由适当的树脂粘合剂固定在一起的，该粘合剂与模制操作期间所注入的树脂是相容的。
8.如权利要求7所述的方法，其特征在于：所述预型件是由碎玻璃纤维构成的。
9.如权利要求7所述的方法，其特征在于：所述预型件是由玻璃纤维织物构成的。
CN91103683A 1990-07-02 1991-06-03 制造风扇叶片的方法 Expired - Fee Related CN1034642C (zh)

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US07/546,806 US5156786A (en) 1990-07-02 1990-07-02 Method for manufacuring fan blades
US07/546,806 1990-07-02
US07/546806 1990-07-02

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DE69114926D1 (de) 1996-01-11
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US5156786A (en) 1992-10-20
MX173885B (es) 1994-04-07
CA2043747C (en) 1995-06-27
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AU7597391A (en) 1992-02-27
CA2043747A1 (en) 1992-01-03
CN1058168A (zh) 1992-01-29
BR9102099A (pt) 1992-01-14
ZA913305B (en) 1992-02-26
EP0465169B1 (en) 1995-11-29
JPH04232713A (ja) 1992-08-21
ID826B (id) 1996-07-24
DE69114926T2 (de) 1996-04-18
AU634377B2 (en) 1993-02-18

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