MULTILAYER COMPOSITE COMPONENT

Abstract

A composite component comprising the following layer construction (a) a first layer consisting at least partially of polyethylene, (b) a second layer consisting at least partially of an elastomer, (c) a third layer consisting at least partially of a thermoset or a thermoplastic, wherein the first layer is arranged directly on the second layer and wherein the second layer is arranged directly on the third layer, and wherein a textile fabric with rovings is arranged between the second layer and the third layer such that some of the rovings are embedded at least in places completely in the second layer, some of the rovings are embedded at least in places completely in the third layer, and some of the rovings are embedded at least in places partially in the second layer and partially in the third layer.

Claims

1. A composite component, comprising: a) a first layer at least partially made of polyethylene; b) a second layer at least partially made of an elastomer; and c) a third layer at least partially made of a thermoset or a thermoplastic, wherein the first layer is arranged directly on the second layer and wherein the second layer is arranged directly on the third layer, and wherein a textile fabric with a plurality of rovings is arranged between the second and the third layer wherein; first portions of the plurality of rovings are embedded completely in the second layer; second portions of the plurality of rovings are embedded completely in the third layer; and third portions of the plurality of rovings are embedded partially in the second layer and partially in the third layer.

2. The composite component as claimed in claim 1, wherein the ISO 1144 Tex value of the individual filaments of the rovings is between 250 and 2500 tex.

3. The composite component as claimed in claim 1, wherein the ISO 1144 Tex value of the individual filaments of the rovings has a value of greater than or equal to 250 tex.

4. The composite component as claimed in claim 1, wherein the first portions of the plurality of rovings, which are embedded completely in the second layer, are interspersed predominantly with the elastomer from the second layer at the places at which the plurality of rovings are embedded in the second layer.

5. The composite component as claimed in claim 1, wherein the second portions of the plurality of rovings, which are embedded completely in the third layer, are interspersed predominantly with the thermoset from the third layer at the places at which the plurality of rovings are embedded in the third layer.

6. The composite component as claimed in claim 1, wherein the third portions of the plurality of rovings, which are embedded partially in the second layer and partially in the third layer, are interspersed predominantly with the elastomer from the second layer or with the thermoset from the third layer at the places at which the plurality of rovings are embedded partially in the second layer and partially in the third layer.

7. The composite component as claimed in claim 1, wherein at least one layer, chose among the first layer and the second layer, has a thickness of 100 to 5000 m.

8. The composite component as claimed in claim 1, wherein the textile fabric is a woven, laid-scrim, knitted or braided fabric.

9. The composite component as claimed in claim 1, wherein the polyethylene is a high molecular weight polyethylene (HMW-PE), an ultra-high molecular weight polyethylene (UHMW-PE) or polytetrafluorethylene (PTFE).

10. The composite component as claimed in claim 1, wherein the elastomer is an ethylene-propylene rubber (EPM), ethylene-propylene-diene rubber (EPDM), ethylene-acrylate rubber (EAM), fluorocarbon rubber (FKM), acrylate rubber (ACM), polyurethane elastomer, ethylene-vinyl acetate (EVA) or acrylonitrile butadiene rubber (NBR).

11. The composite component as claimed in claim 1, wherein the plurality of rovings are made of UHMW-PE fibers, carbon fibers, glass fibers, aramid fibers or mixtures thereof.

12. The composite component as claimed in claim 1, wherein the thermoset or the thermoplastic is a polymeric resin system based on epoxide, polyurethane, methyl methacrylate, (meth)acrylate or (meth)acrylamide.

13. The composite component as claimed in claim 1, wherein: the textile fabric is a woven or laid-scrim fabric, the plurality of rovings made of glass fibers, the polyethylene is an ultra-high molecular polyethylene (UHMW-PE), the elastomer is an ethylene-propylene-diene rubber (EPDM), and the thermoset is a polymeric resin system based on epoxide.

14. The composite component as claimed in claim 1, wherein the composite component is a rotor blade.

15. A wind turbine comprising a composite component as claimed in claim 1.

16. A method for producing a composite component comprising: providing a first reaction mixture configured to produce an elastomer; coating a surface of a first layer at least partially made of polyethylene with the provided first reaction mixture; placing a textile fabric onto the coated reaction mixture so that some portions of the rovings are embedded completely in the first reaction mixture; vulcanizing the first reaction mixture to form a second layer comprising at least partially an elastomer; providing a second reaction mixture configured to produce a thermoset or thermoplastic; coating the second layer with the second reaction mixture so that some portions of the rovings are embedded completely in the second reaction mixture; and curing the second reaction mixture to form a third layer comprising consisting at least partially a thermoset or thermoplastic.

17. The method as claimed in claim 16, wherein the composite component is used to form a portion of a rotor blade.

18. The composite component as claimed in claim 7 wherein both the first layer and the second layer have thicknesses between 300 to 900 m.

19. The composite component as claimed in claim 15, wherein the composite component is at least a portion of a rotor blade of the wind turbine.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0127] In the context of the present invention, it is preferred for two or more of the aspects denoted above as being preferred to be realized at the same time; especially preferred are the combinations of such aspects and of the corresponding features that are evident from the appended claims.

[0128] FIG. 1 shows a diagrammatic representation of a wind power installation with rotor blade element in accordance with the invention;

[0129] FIG. 2 shows diagrammatically one embodiment of a rotor blade element in accordance with the invention; and

[0130] FIG. 3 shows in diagrammatic representation a detail of the rotor blade element from FIG. 2.

DETAILED DESCRIPTION

[0131] FIG. 1 shows a wind power installation 1000 having a tower 1200 and a nacelle 1300. Arranged on the nacelle 1300 is a rotor 1400 having three rotor blades 1100 and a spinner 1500. In operation, the rotor 1400 is set into rotational motion by the wind and thereby drives a generator in the nacelle 1300. The rotor blades 1100 of the wind power installation 1000 possess a basis (layer 13) comprising a thermoset which is coated in places with a surface foil (layer 11) of polyethylene; an elastomer layer (layer 12) is located between the surface foil and the basis. This construction is elucidated in more detail with reference to the subsequent figures.

[0132] FIG. 2 shows a rotor blade element 1110 of the rotor blade 1100, specifically the leading rotor blade edge. The leading rotor blade edge 1110 possesses a surface foil 11. This foil consists, in this working example, of ultrahigh molecular weight polyethylene (UHMW-PE). The surface foil 11 (layer 11) is joined via an attachment layer 12 (layer 12) to the basis of the rotor blade element 13 (layer 13). The basis 13 (layer 13) of the rotor blade element consists here at least partially of a thermoset. In the working example, the thermoset is an epoxy resin. The attachment layer 12 (layer 12) consists at least partially of an elastomer. As a result of the attachment of the surface foil 11 (layer 11) to the basis 13 (layer 13) by means of an elastomer, it is possible to join UHMW-PE to epoxy resin. The UHMW-PE surface foil 11 (layer 11) is particularly resistant to abrasive loads of the kind occurring during operation of wind power installations, especially at the rotor edges.

[0133] FIG. 3 shows a detail of the rotor blade element 1110. At this place on the rotor blade element 1110, the rotor blade element 1110 possesses the following layer construction: A first layer 11 consisting at least partially of polyethylene, a layer 12 consisting partially of an elastomer, and at least one layer 13 as basis, consisting at least partially of a thermoset. A textile fabric 14 with rovings 15, 16, 17 is arranged between the layer 12 and 13 such that some of the rovings 15 are embedded at least in places completely in the layer 12, some of the rovings 16 are embedded at least in places completely in the layer 13, and some of the rovings 17 are embedded at least in places partially in the layer 12 and partially in the layer 13. In this working example, the rovings consist of glass fibers, the thermoset is an epoxy resin, the polyethylene is an ultrahigh molecular weight polyethylene (UHMW-PE), and the elastomer is EPDM.