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Patent Searching and Data


Title:
MANUFACTURING METHOD AND TOOL FOR CARBON PARTS
Document Type and Number:
WIPO Patent Application WO/2019/211141
Kind Code:
A2
Abstract:
Method of manufacturing a product including at least two carbon parts (50) comprises the step of: - manufacturing a first carbon part (50), - manufacturing at least a second carbon part (50), - providing on a surface (51) of one of the first carbon part or second carbon part (50) a plurality of protrusions (52, 53) including a carbon resin, - joining together the first carbon part and the second carbon part (50) in such a way that the plurality of protrusions (52, 53) is interposed between the first carbon part and second carbon part (50) for providing physical and electrical connection.

Inventors:
PEDERSEN, David Stien (Birkevej 4, 9000 Aalborg, 9000, DK)
Application Number:
EP2019/060519
Publication Date:
November 07, 2019
Filing Date:
April 24, 2019
Export Citation:
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Assignee:
SIEMENS GAMESA RENEWABLE ENERGY A/S (Borupvej 16, 7330 Brande, 7330, DK)
International Classes:
B29C70/52; B29C45/14; B29C65/00; B29C65/48; B29C70/88; F03D1/06; F03D80/30
Other References:
None
Attorney, Agent or Firm:
ASPACHER, Karl-Georg (Postfach 22 16 34, M√ľnchen, 80506, DE)
Download PDF:
Claims:
CLAIMS

1. Method of manufacturing a product including at least two carbon parts (50), the method comprising the step of:

- manufacturing a first carbon part (50),

- manufacturing at least a second carbon part (50),

- providing on a surface (51) of one of the first carbon part or second carbon part (50) a plurality of protrusions (52,

53) including a carbon resin,

- joining together the first carbon part and the second car bon part (50) in such a way that the plurality of protrusions (52, 53) is interposed between the first carbon part and the second carbon part (50) for providing physical and electrical connection .

2. Method of manufacturing as claimed in claim 1, wherein the plurality of protrusions (52, 53) comprises at least one dot ( 52 ) .

3. Method of manufacturing as claimed in claim 1 or 2, wherein the plurality of protrusions (52, 53) comprises at least one strip (53) .

4. Method of manufacturing as claimed in any of the previ ous claims 1 to 3, wherein plurality of protrusions (52, 53) is injected on the surface (51) of one of the first carbon part or second carbon part (50) .

5. Method of manufacturing as claimed in any of the previ ous claims 1 to 3, wherein plurality of protrusions (52, 53) is deposited on a surface (51) of one of the first carbon part or second carbon part (50) .

6. Method of manufacturing as claimed in any of the previ ous claims, wherein the plurality of protrusions (52, 53) is organized in a pattern.

7. Method of manufacturing as claimed in any of the previ ous claims, wherein at least one of the first carbon part and second carbon part (50) is manufactured by pultrusion.

8. Method of manufacturing as claimed in claim 7, wherein the plurality of protrusions (52, 53) is provided on a sur face (51) of one of the first carbon part or second carbon part (50) during a pultrusion step.

9. Method of manufacturing as claimed in claim 8, wherein the plurality of protrusions (52, 53) is deposited on a sur face (51) of one of the first carbon part or second carbon part (50) inside a pultrusion die.

10. Method of manufacturing as claimed in any of the previ ous claims, wherein one of the first carbon part or second carbon part (50) is a portion of a wind turbine blade (4) .

11. Pultrusion die (20) longitudinally extending along a pultrusion direction (X) between a first inlet section (21) for receiving a plurality of fibers (110) and a second outlet section (22) for delivering a plurality of resin-soaked fi bers, wherein the pultrusion die (20) comprises a band (25) including a plurality of protrusions (52, 53) including a carbon resin, the band (25) being disposed in such a way that the plurality of protrusions (52, 53) is transferred from the band (25) to the plurality of fibers (110) when the plurality of fibers (110) crosses the pultrusion die (20) from the in let section (21) to the outlet section (22) .

12. Pultrusion die (20) as claimed in claim 11, wherein the band (25) is annularly shaped around a band axis (Z) , trans versal to the pultrusion direction (X) , the annular band (25) being able to rotate around the band axis (Z) .

Description:
DESCRIPTION

Manufacturing method and tool for carbon parts

Field of invention

The present invention relates to a manufacturing method for improving the conductivity of carbon parts. The present in vention further relates to a tool for pultrusion manufactur ing of carbon parts with improved conductivity.

Art Background

Carbon parts are normally used in various industrial fields. For example, carbon parts may be used in manufacturing blades for wind turbines to be able to make them longer and less heavy compared to blades manufactured using glass fiber mate rial only. Such carbon parts may be typically manufactured through a pultrusion process.

In constructions of great dimensions like wind turbine, elec trically conducting parts normally need to be electrical con nected to the lightning protection system, including carbon parts of wind turbine blades, because carbon is an electrical conducting material.

To provide an efficient lightning protection system it is im portant that a good conductivity between contacting parts is achieved. This requires controlling the surface of contact between contacting parts. In case carbon parts are present, controlling the surface of contact between contacting parts may be problematic because the surfaces of such components, for example manufactured through pultrusion, are typically irregular .

One known solution to improve the electrical conduction be tween carbon parts is that of sanding the parts and inserting carbon fiber mattes between them.

Another known solution is that of bolting the carbon parts together on a lot of places. Both these solutions are however time consuming and increase the material cost.

It is therefore still needed to provide a manufacturing pro cess for manufacturing a product including at least two car bon parts, where the electrical conductivity between the car bon parts is improved in an efficient way, by reducing the manufacturing time and the material costs, with respect to the prior art.

Summary of the Invention

This need may be met by the subject matter according to the appended independent claims. Advantageous embodiments of the present invention are described by the dependent claims.

According to a first aspect of the invention, a method of manufacturing a product including at least two carbon parts is provided. The method comprises the step of:

- manufacturing a first carbon part,

- manufacturing at least a second carbon part,

- providing on a surface of one of the first carbon part or second carbon part a plurality of protrusions including a carbon resin,

- joining together the first carbon part and second carbon part in such a way that the plurality of protrusions is in terposed between the first carbon part and second carbon part for providing physical and electrical connection.

The plurality of conducting protrusions permits improving the contact between the two carbon parts, with less material and costs, with respect to the prior art. Further, the distribu tion of protrusions can be controlled, thus providing the further advantage that the physical and electrical contact between the carbon parts can be provided with precision were desired . According to embodiments of the present invention, the plu rality of protrusions may comprise one or more dots, one or more strips, or a combination of dots and strips.

Dots and strips may be injected or deposited.

Dots and strips may be organized in a pattern.

According to specific embodiments of the present invention at least one of the first carbon part and second carbon part to be joined is manufactured by pultrusion. In such embodiments, the plurality of protrusions is provided on a surface of one of the first carbon part or second carbon part during a pul trusion step. In particular, the plurality of protrusions may be deposited on a surface of one of the first carbon part or second carbon part inside a pultrusion die.

According to a second aspect of the invention, a pultrusion die is provided. The pultrusion die longitudinally extends along a pultrusion direction between a first inlet section for receiving a plurality of fibers and a second outlet sec tion for delivering a plurality of resin-soaked fibers, wherein the pultrusion die comprises a band including a plu rality of protrusions including a carbon resin, the band be ing disposed in such a way that the plurality of protrusions is transferred from the band to the plurality of fibers when the plurality of fibers crosses the pultrusion die from the inlet section to the outlet section.

According to an embodiment of the present invention the band is annularly shaped around a band axis, transversal to the pultrusion direction, the annular band being able to rotate around the band axis.

The pultrusion die above described permits, during a pultru sion process, the automatization of the protrusions deposi tions on the carbon parts to be later joined together

The present invention may be advantageously used to manufac ture carbon parts including carbon resin protrusions to be integrated in a wind turbine blade. It has to be noted that embodiments of the invention have been described with reference to different subject matters.

In particular, some embodiments have been described with ref erence to device (pultrusion die) type claims whereas other embodiments have been described with reference to method type claims. However, a person skilled in the art will gather from the above and the following description that, unless other notified, in addition to any combination of features belong ing to one type of subject matter also any combination be tween features relating to different subject matters, in par ticular between features of the method type claims and fea tures of the apparatus type claims is considered as to be disclosed with this document.

The aspects defined above and further aspects of the present invention are apparent from the examples of embodiment to be described hereinafter and are explained with reference to the examples of embodiment. The invention will be described in more detail hereinafter with reference to examples of embodi ment but to which the invention is not limited.

Brief Description of the Drawing

Figure 1 shows a schematic axonometric view of a first

product obtained with the method of the present invention .

Figure 2 shows a schematic axonometric view of a second product obtained with the method of the present invention .

Figure 3 shows a schematic axonometric view of pultrusion die according to the present invention. Figure 4 shows a schematic section of a wind turbine in cluding a rotor blade comprising a product manu factured according to the present invention.

Detailed Description

The illustrations in the drawings are schematic. It is noted that in different figures, similar or identical elements are provided with the same reference signs.

Figure 1 shows a carbon part 50 on which plurality of protru sions 52 including a carbon resin are deposited or injected over a surface 51 of the carbon part 50.

Particularly the carbon part 50 is made of a composite mate rial including a plurality of carbon fibers and a resin.

The protrusions 52 are in form of dots and are distributed according to a rectangular pattern including columns and rows .

According to other embodiments of the invention (not shown) the plurality of dots 52 may be distributed according to any other pattern.

The carbon part 50 may be joined to another carbon part (not shown) , in such a way that the plurality of protrusions are interposed between the first carbon part and second carbon part for providing physical and electrical connection. The protrusions 52 may be provided on both carbon parts to be joined .

Figure 2 shows a carbon part 50 on which a plurality of pro trusions 53 including a carbon resin are deposited or inject ed over a surface 51.

Differently from the embodiment of figure 1, the protrusions 53 are in form of parallel strips. In case the carbon part 50 is a composite material including a plurality of carbon fi bers the strips 50 may be orthogonal or parallel or inclined with respect to the strips 50. Figure 3 shows a pultrusion die 20, which can be used for au tomatically depositing the plurality of protrusions dots 52 of the embodiment of figure 1.

The pultrusion die 20 longitudinally extends along a pultru sion direction X between a first inlet section 21 for receiv ing a plurality of fibers 110 and a second outlet section 22 for delivering a plurality of resin-soaked fibers.

The pultrusion die 20 comprises a band 25 including the plu rality of protrusions 52.

The band 25 is annularly shaped around a band axis Z, trans versal to the pultrusion direction X, and is able to rotate around the band axis Z.

According to other embodiments (not shown) of the present in vention, the band is open and extends between two band ends. In both embodiments at least a portion of the band translates between the inlet section 21 and the outlet section 22.

The band 25 is disposed along an inner side of the pultrusion die 20, in such a way that the plurality of protrusions 52 are transferred from the band 25 to the plurality of fibers 110 when the plurality of fibers 110 crosses the pultrusion die 20 from the inlet section 21 to the outlet section 22. According to other embodiments of the invention (not shown) , the pultrusion die 20 comprises the plurality of strip pro trusions 53 to be transferred to the plurality of fibers 110.

Figure 4 shows a wind turbine 1 according to the invention. The wind turbine 1 comprises a tower 2, which is mounted on a non-depicted fundament. A nacelle 3 is arranged on top of the tower 2.

The wind turbine 1 further comprises a wind rotor 5 having two, three or more blades 4 (in the perspective of Figure 1 only two blades 4 are visible) . The wind rotor 5 is rotatable around a rotational axis Y. The blades 4 extend radially with respect to the rotational axis Y.

The wind rotor 5 is rotationally coupled with an electric generator 30 by means of a rotatable main shaft 9.

According to other possible embodiments of the present inven tion (not represented in the attached figures) , the wind ro- tor 5 is rotationally coupled directly with the electric gen erator 30 (direct-drive generator configuration) .

A schematically depicted bearing assembly 8 is provided in order to hold in place the rotor 5. The rotatable main shaft 9 extends along the rotational axis Y.

The blades 4 comprise one or more carbon parts 50 obtained through the present invention. Such carbon parts 50 are joined to other portions of the blades, which may be also ob tained according to the present invention, in order to im- prove the electrical conductivity of the overall blades. This improves the performances of the lightning protection system of the blade 4.