{DESCRIPTION}
{Title of Invention}
REINFORCEMENT FABRIC LAMINATING APPARATUS AND METHOD FOR THE
SAME
{Technical Field}
{0001}
The present invention relates to a fiber-reinforced base
material laminating apparatus and a method for the same, and
in particular, to a method for laminating a sheet-like fiber-
reinforced base material on a curved or bent mold.
{Background Art}
{0002}
Fiber-reinforced plastics (FRPs) or the like are
generally used as lightweight and high-strength composite
materials in large structural members for aircraft,
architecture, wind turbines, etc. Fiber reinforced plastics
are formed by laminating a fiber-reinforced base material on a
mold, followed by impregnating it with plastic, and curing the
impregnated plastic. Apparatuses for laminating a fiber-
reinforced base material on a mold are disclosed in Patent
Literatures 1 to 3.
{Citation List}
{Patent Literature}
{0003}
{PTL 1} Japanese Examined Patent Application, Publication No.
Hei 6-39133
{PTL 2} Japanese Unexamined Patent Application, Publication
No. Hei 5-254724
{PTL 3} Japanese Unexamined Patent Application, Publication
No. 2006-335049
{Summary of Invention}
{Technical Problem}
{0004}
However, lamination of a sheet-like fiber-reinforced base
material (hereinafter referred to as "reinforcement fabric")
onto a large curved or bent mold is often performed manually,
which takes much time for the laminating operation, thus
causing the problem of reduced operating efficiency. This
also causes a problem in that wrinkles etc. occur when the
reinforcement fabric is laminated, thus causing variations in
quality.
The invention disclosed in Patent Literature 1 laminates
a roving material or a thread-like reinforcement fabric.
Patent Literature 2 discloses an apparatus that forms a
reinforcement fabric into a tape and laminates the tape on a
mold while pressure-contacting it with the mold by pressing
the entire fiber width with a roller having the same width as
the reinforcement fabric; however, a specific method for
laminating a sheet-like reinforcement fabric is not disclosed.
Patent Literature 3 discloses a gate-shaped apparatus
that laminates a reinforcement fabric on a mold; however, it
has the problem of high installation cost because of the
large-scale apparatus.
{0005}
The present invention has been made in consideration of
such circumstances and provides a reinforcement fabric
laminating apparatus and a method for the same in which
wrinkles that occur when a sheet-like reinforcement fabric is
laminated on a curved or bent mold can be prevented, the
workload can be reduced, and the operating efficiency can be
improved.
{Solution to Problem}
{0006}
To solve the above problems, the reinforcement fabric
laminating apparatus and the method for the same of the
present invention adopt the following solutions.
A first aspect of the present invention is a
reinforcement fabric laminating apparatus including a sheet
feeding unit that feeds out a reinforcement fabric to be
laminated on a mold and a pressure contact unit that pressure-
contacts the reinforcement fabric onto the mold, wherein the
pressure contact unit has a narrower width than the
reinforcement fabric, and the sheet feeding unit supplies the
reinforcement fabric while applying tension between the sheet
feeding unit and the pressure contact unit.
{0007}
The reinforcement fabric laminating apparatus according
to the first aspect of the present invention feeds out the
reinforcement fabric to the mold while applying tension and
pressure-contacts the reinforcement fabric onto the mold while
maintaining the tension. Since the reinforcement fabric is
pressure-contacted using the pressure contact unit that is
smaller in width than the reinforcement fabric, the pressure
contact part is restricted to a predetermined position of the
mold, but a non-pressure-contact part of the reinforcement
fabric is not restricted to the mold, and thus, the
reinforcement fabric is deformed due to the tension between
the sheet feeding unit and the pressure contact unit and is
relatively displaced (shifts) in the tensile direction. Thus,
even if the mold has a curved surface, the reinforcement
fabric can be laminated on the mold so as to follow it without
being wrinkled. Accordingly, the reinforcement fabric wider
than the pressure contact unit can be laminated on the mold
without being wrinkled.
The reinforcement fabric is a sheet-like fabric made of
reinforced fibers, such as glass fibers or carbon fibers, and
having a width of, for example, about 1 m. By laminating a
reinforcement fabric on a mold with the reinforcement fabric
laminating apparatus of the present invention, thereafter
impregnating it with plastic using a VaRTAM method or the
like, and curing it, a composite (fiber-reinforced plastic)
serving as a structural member is manufactured.
{0008}
The reinforcement fabric laminating apparatus according
to the first aspect of the present invention may have a
configuration in which the pressure contact unit pressure-
contacts the central portion of the reinforcement fabric.
{0009}
With this configuration, the reinforcement fabric is fed
out onto the mold while being subjected to tension, with the
central portion pressure-contacted. The right and left (both
sides) of the reinforcement fabric whose central portion is
pressure-contacted are therefore uniformly subjected to force.
This allows the right and left of the reinforcement fabric
whose central portion is pressure-contacted to be laminated
onto the mold without being wrinkled.
{0010}
The reinforcement fabric laminating apparatus according
to the first aspect of the present invention may have a
configuration in which the tension of the reinforcement fabric
fed out from the sheet feeding unit is generated due to
frictional resistance of the sheet feeding unit.
{0011}
With this configuration, the reinforcement fabric
receives tension due to the frictional resistance of the
reinforcement fabric feeding unit. This allows the tension of
the reinforcement fabric to be generated without providing an
additional mechanism for generating the tension. Accordingly,
because the reinforcement fabric is fed out onto the mold
while tension is generated therein and is pressure-contacted
onto the mold by the pressure contact unit, the reinforcement
fabric can be laminated onto the mold without being wrinkled.
"Frictional resistance" means, for example, resistance
generated along with the motion of feeding out the
reinforcement fabric, and if the reinforcement fabric feeding
unit is composed of a fiber roll and a bearing that supports
the core of the roll or a shaft passing through the core of
the roll, the frictional resistance can be achieved by
employing a bearing member in which sliding friction occurs on
the bearing.
{0012}
The reinforcement fabric laminating apparatus according
to the first aspect of the present invention may have a
configuration in which the sheet feeding unit includes an
adhesive supply unit that supplies an adhesive for bonding the
reinforcement fabric and the mold together.
{0013}
With this configuration, the reinforcement fabric
laminating apparatus includes the adhesive supply unit. The
reinforcement fabric laminating apparatus can therefore
perform bonding of the reinforcement fabric onto the mold, as
well as feeding, wrinkle smoothing, and pressure contacting.
Thus, the efficiency of the reinforcement fabric laminating
operation can be improved.
{0014}
The reinforcement fabric laminating apparatus according
to the first aspect of the present invention may have a
configuration in which the mold is for forming a large fiber-
reinforced plastic product, such as a wind turbine blade, by
laminating the reinforcement fabric thereon; the sheet feeding
unit includes a handle; and the pressure contact unit includes
a pressure contact roller and a driving unit that drives the
pressure contact roller.
{0015}
With this configuration, the reinforcement fabric
laminating apparatus is provided with the pressure contact
roller and the driving unit that drives the pressure contact
roller and can be moved under manual control by operating the
handle. The operation of laminating the reinforcement fabric
onto the mold can be therefore performed with the simple
reinforcement fabric laminating apparatus. This allows the
operation of laminating the reinforcement fabric for forming a
wind turbine blade, which has been performed manually by a
large number of persons, to be performed by a small number of
persons, thus allowing reduction in labor costs and
improvement in operating efficiency.
{0016}
The reinforcement fabric laminating apparatus according
to the first aspect of the present invention may include an
auxiliary pressure contact unit that pushes the reinforcement
fabric onto the mold.
{0017}
With this configuration, a larger area of the
reinforcement fabric is pressure-contacted onto the mold by
the auxiliary pressure contact unit. The pressure contact
force of the auxiliary pressure contact unit is set smaller
than the pressure contact force of the pressure contact unit,
which need only prevent the reinforcement fabric from peeling
off from the top side of the mold. This can therefore prevent
the reinforcement fabric from peeling off from the top side of
the mold, thus allowing the fibers to be laminated on a more
complicated curved surface without being wrinkled.
{0018}
The reinforcement fabric laminating apparatus according
to the first aspect of the present invention may include a
movable unit to which the sheet feeding unit and the pressure
contact unit are connected, wherein the movable unit may be
moved along the longitudinal direction of the mold and can
freely move the sheet feeding unit and the pressure contact
unit in the widthwise direction of the mold and in a vertical
direction perpendicular to the longitudinal direction and the
widthwise direction of the mold.
{0019}
With this configuration, the sheet feeding unit and the
pressure contact unit can be freely moved in the longitudinal
direction of the mold and in the vertical direction
perpendicular to the longitudinal direction and the widthwise
direction of the mold. This allows the pressure contact unit
to be freely moved on the mold by moving the movable unit even
if the reinforcement fabric is laminated on the curved or bent
mold. Accordingly, the reinforcement fabric can be laminated
on even the curved or bent mold without the pressure contact
unit being separated from the top side of the mold.
By moving the movable unit, the sheet feeding unit and
the pressure contact unit can be moved in the vertical
direction perpendicular to the longitudinal direction and the
widthwise direction of the mold during replacement of the
fiber-reinforced sheet feeding means and the fiber-reinforced
sheet roll and maintenance of the pressure contact unit. This
facilitates replacement of the fiber-reinforced sheet feeding
means and the fiber-reinforced sheet roll and maintenance of
the pressure contact unit
Furthermore, since the sheet feeding unit and the
pressure contact unit can be continuously moved in the
longitudinal direction of the mold, the reinforcement fabric
can easily be laminated on a mold of a large member.
{0020}
A second aspect of the present invention is a laminating
method for a reinforcement fabric laminating apparatus having
a sheet feeding unit that feeds out a reinforcement fabric to
be laminated on a mold and a pressure contact unit that
pressure-contacts the reinforcement fabric onto the mold,
wherein the pressure contact unit has a narrower width than
the reinforcement fabric, and the sheet feeding unit supplies
the reinforcement fabric while applying tension between the
sheet feeding unit and the pressure contact unit.
{Advantageous Effects of Invention}
{0021}
The reinforcement fabric laminating apparatus according
to the present invention feeds out a reinforcement fabric onto
a mold while applying tension and pressure-contacts the
reinforcement fabric onto the mold while maintaining the
tension. Since the reinforcement fabric is pressure-contacted
using the pressure contact unit that is smaller in width than
the reinforcement fabric, a non-pressure-contact part of the
reinforcement fabric is deformed due to the tension between
the sheet feeding unit and the pressure contact unit and is
relatively displaced in the tensile direction. Thus, even if
the top side of the mold has a curved surface, the
reinforcement fabric can be laminated on the mold.
Accordingly, the reinforcement fabric wider than the pressure
contact unit can be laminated on the mold without being
wrinkled.
{Brief Description of Drawings}
{0022}
{Fig. 1} Fig. 1 is a side view of a reinforcement fabric
laminating apparatus according to a first embodiment of the
present invention.
{Fig. 2} Fig. 2 is a front view of the reinforcement fabric
laminating apparatus shown in Fig. 1.
{Fig. 3A} Fig. 3A is a perspective view of a mold according
to the first embodiment.
{Fig. 3B} Fig. 3B is a partial enlarged diagram of part A
shown in Fig. 3A.
{Fig. 4A} Fig. 4A is a partial enlarged perspective view of
the reinforcement fabric and the mold shown in Fig. 1.
{Fig. 4B} Fig. 4B shows, in the upper diagram, a partial
enlarged plan view of the reinforcement fabric and the mold
shown in Fig. 1, and in the lower diagram, a side view in
which the reinforcement fabric is laminated on the arc length
formed on the mold.
{Fig. 5} Fig. 5 shows the reinforcement fabric, in which the
upper diagram is a plan view of the reinforcement fabric, and
the lower diagram is a side view thereof.
{Fig. 6} Fig. 6 is a side view of a reinforcement fabric
laminating apparatus according to a second embodiment of the
present invention.
{Fig. 7} Fig. 7 is a perspective view of a reinforcement
fabric laminating apparatus according to a third embodiment of
the present invention.
{Description of Embodiments}
{0023}
{First Embodiment}
A reinforcement fabric laminating apparatus according to
a first embodiment of the present invention will be described
on the basis of Figs. 1 and 2.
A reinforcement fabric laminating apparatus 1 according
to this embodiment includes a sheet feeding mechanism (sheet
feeding unit) 2 and a pressure contact roller (pressure
contact unit) 3 that pressure-contacts a reinforcement fabric
14 fed out from the sheet feeding mechanism 2 onto an airfoil
(mold) 15.
{0024}
The sheet feeding mechanism 2 includes a sheet roll 2a
and a roll shaft 2b. The roll shaft 2b passes through the
center of the sheet roll 2a. The sheet roll 2a is formed such
that a reinforcement fabric 14 fed out is wound therearound.
The reinforcement fabric 14 is wound so that the direction of
the fibers coincides with the longitudinal direction of the
airfoil 15, that is, in the feeding direction.
{0025}
The pressure contact roller 3 includes a pressure contact
roller portion 3a and a pressure contact roller shaft 3b. The
pressure contact roller portion 3a pressure-contacts the
reinforcement fabric 14 to be fed out from the sheet roll 2a
onto the airfoil 15. The pressure contact roller shaft 3b
passes through the center of the pressure contact roller
portion 3a. The pressure contact roller portion 3a and the
pressure contact roller shaft 3b are narrower than the sheet
roll 2a, that is, the width of the reinforcement fabric 14.
The airfoil 15 is weighted by the pressure contact roller 3
and the sheet feeding mechanism 2 etc. located above the
pressure contact roller 3 via the pressure contact roller
portion 3a. Due to the weight applied via the pressure
contact roller portion 3a, the reinforcement fabric 14 fed out
from the sheet roll 2a is pressure-contacted onto the airfoil
15.
{0026}
A motor (driving unit) 9 is provided at one end of the
pressure contact roller shaft 3b. The motor 9 is a driving
source that rotationally drives the pressure contact roller
shaft 3b. The pressure contact roller portion 3a is rotated
by the pressure contact roller shaft 3b being rotationally
driven.
{0027}
The sheet feeding mechanism 2 is supported from below by
two frames 13a and 13b. Ends of the frames 13a and 13b (in
Fig. 2, the upper ends) are connected to both ends of the roll
shaft 2b (see Fig. 1) of the sheet feeding mechanism. The
other ends of the frames 13a and 13b (in Fig. 2, the lower
ends) are connected to both ends of the pressure contact
roller shaft 3b. The frames 13a and 13b extend from the roll
shaft 2b of the sheet feeding mechanism 2 diagonally downwards
to the pressure contact roller shaft 3b. Because the width of
the pressure contact roller shaft 3b is smaller than the width
of the roll shaft 2b of the sheet feeding mechanism 2, the
distance between the two frames 13a and 13b decreases
gradually from the roll shaft 2b to the pressure contact
roller shaft 3b, as shown in Fig. 2. In this embodiment, this
allows the pressure contact roller 3 to pressure-contact the
central portion of the reinforcement fabric 14. Furthermore,
the frame 13c for supplying an adhesive is connected to both
ends of the roll shaft 2b of the sheet feeding mechanism 2 so
as to be parallel to the roll shaft 2b. The frame 13c for
supplying an adhesive is provided in the vicinity of the sheet
roll 2a.
{0028}
Two handles 8 (see Fig. 1) extend from both ends of the
roll shaft 2b so as to be parallel to the top side of the
airfoil 15 and parallel to each other when an operator grips
grippers. The grippers that the operator grips are provided
at the other ends of the handles 8 (in Fig. 1, the right
ends) . The handles 8 and the frames 13 are connected so as to
for an acute angle when viewed from the side, as shown in Fig.
1.
{0029}
An adhesive supply unit 7 includes an adhesive spray
nozzle 7a and an adhesive supply tank (not shown). The
adhesive supply tank is accommodated in, for example, the
adhesive supply frame 13c. The adhesive spray nozzle 7a is
provided at one or a plurality of (in this embodiment, three)
locations on the adhesive supply frame 13c. Since the
adhesive supply frame 13c and the adhesive supply unit 7 are
provided in the vicinity of the sheet roll 2a, the adhesive
can be sprayed onto the surface of the sheet roll 2a.
{0030}
The airfoil 15 (see Figs. 3A and 3B) used in this
embodiment is shaped in the form of a blade (not shown) of a
wind turbine (not shown). The mold 15 of a wind turbine blade
is divided, with the leading edge and the trailing edge of the
blade as a dividing line, into two, that is, the front, which
is a wind receiving surface, and the back, which is opposite
thereto. The airfoil 15 in Fig. 3A is a rear-side airfoil 15.
The reinforcement fabric 14 is laminated on the airfoil
15 by the reinforcement fabric laminating apparatus 1
according to this embodiment, is then impregnated with plastic
using a VaRAM method or the like, and is cured. Thus,
composites (fiber-reinforced plastic) for the front and back
of the blade are formed. The blade is formed by combining the
front and back composites manufactured in this way.
{0031}
The rear-side airfoil 15 shown in Fig. 3A is placed with
a surface on which the reinforcement fabric 14 (see Fig. 1) is
laminated facing up. The airfoil 15 extends in the
longitudinal direction thereof and curves in a concave shape
(downwardly convex shape) in the widthwise direction of the
airfoil 15 (in a chord direction in a blade section).
Furthermore, as shown in Fig. 3B, which is a partial enlarged
diagram of part A in Fig. 3A, the part of the surface of the
airfoil 15 on which the reinforcement fabric 14 is laminated
has a saddle shape (non-Euclidean) having a convex shape in
the longitudinal direction of the airfoil 15 and a concave
shape in the widthwise direction of the airfoil 15. In other
words, the surface of the airfoil 15 on which the
reinforcement fabric 14 is laminated is shaped so that arcs
AB, EG, and DC formed in the longitudinal direction of the
airfoil 15 form upwardly convex arcs, and arcs AD, FH, and BC
formed in the widthwise direction of the airfoil 15 form
concave arcs. Therefore, a surface ABCD formed by connecting
the ends A, B, C, and D of the individual arcs forms a concave
shape as a whole. The arcs AB and DC and the arc EG are
shaped such that the radius Re of the arc EG is smaller than
the radii Re of the arcs AB and DC.
{0032}
Figs. 4A and 4B show the principle in which the
reinforcement fabric 14 is wrinkled when the flat
reinforcement fabric 14 is pressure-contacted with the saddle-
shaped airfoil 15 with the fiber direction is aligned with the
longitudinal direction of the airfoil 15.
As shown in Fig. 4A, the longitudinal direction of the
airfoil 15 and the fiber direction of the reinforcement fabric
14 are set in the same direction. The reinforcement fabric 14
are laminated so as to be simply pressed from directly above
so that two sides A'D' and B'C of the reinforcement fabric 14
are aligned with the arcs AD and BC that are in the widthwise
direction of the airfoil 15.
{0033}
When the airfoil 15 and the reinforcement fabric 14 in
Fig. 4A are viewed from the side, the surface ABCD of the
airfoil 15 (see Fig. 4A) is formed of arcs that are concave
from the arcs AB and DC toward the arc EG, as shown in the
lower diagram in Fig. 4B. Therefore, when the airfoil 15 is
viewed from the side, the arc EG is located below the arcs AB
and DC. The arc length EG is shorter than the arc lengths AB
and DC. The lengths of arcs in the longitudinal direction
that form the surface ABCD of the airfoil 15 (see Fig. 4A)
increase from the arc length EG toward the arc length AB or
DC. On the other hand, since a surface A'B'C'D' of the
reinforcement fabric 14 has a planar shape, the lengths of two
sides A'B' and D'C thereof and the length of a central
portion E'G' in the longitudinal direction that connects the
midpoints E' and G' of the two sides A'D' and B'C are equal.
{0034}
Consequently, the central portion E'G' in the
longitudinal direction of the reinforcement fabric 14 is
longer than the arc length EG of the airfoil 15. Therefore,
when the reinforcement fabric 14 is laminated on the airfoil
15 in such a manner that the two sides A'D' and B'C are
aligned with the arcs AD and BC of the airfoil 15, wrinkles
occur in the vicinity of the widthwise central portion F'H'
that connects the respective midpoints F' and H' of the two
sides A'B' and D'C of the reinforcement fabric 14, as shown
in the upper diagram of Fig. 4B. This is because the lengths
of the longitudinal arcs that form the surface ABCD of the
airfoil 15 (see Fig. 4A) increase from the arc EG toward the
arcs AB and DC, as described above. The wrinkles that occur
in the vicinity of the widthwise central portion F'H' of the
reinforcement fabric 14 decrease with an increasing distance
to the side A'B' (see Fig. 4B) or the side D'C (see Fig. 4B)
of the reinforcement fabric 14.
{0035}
Fig. 5 shows the reinforcement fabric 14. In Fig. 5, the
upper diagram is a plan view of the reinforcement fabric 14,
and the lower diagram is a side view thereof. Fig. 5 shows a
state in which the reinforcement fabric 14 shifts in the fiber
direction (longitudinal direction).
The reinforcement fabric 14 is a fabric in which
continuous fiber bundles 14a, 14b, 14c, ... made of, for
example, about 5-mm wide glass fibers or carbon fibers, are
arrayed in parallel along the longitudinal direction of the
airfoil 15 (see Figs. 3A and 3B) and which has a width of
about 1 m. Because the reinforcement fabric has high
elasticity, the reinforcement fabric 14 has the characteristic
of not being stretched in the longitudinal direction by an
acting force generated due to a pressure contact force during
lamination.
{0036}
On the other hand, as shown in the upper diagram of Fig.
5, if the central portion of the reinforcement fabric 14 is
pressure-contacted, so that a force in the longitudinal
direction of the airfoil 15 (see Figs. 3A and 3B) is applied
thereto, the continuous fiber bundles 14c and 14e on which no
pressure contact force is exerted are drawn by tension exerted
on the reinforcement fabric 14, relative to the central
continuous fiber bundle 14d on which the pressure contact
force is exerted, the reinforcement fabric 14 can be shifted
in the longitudinal direction of the airfoil 15 (see Figs. 3A
and 3B) . Using this characteristic allows the reinforcement
fabric 14 to be laminated on the saddle-shaped airfoil 15 (see
Figs. 3A and 3B) without being wrinkled.
{0037}
If the reinforcement fabric 14 is pressure-contacted from
one end at the center along the longitudinal direction, the
fibers shift in the pressure contact direction; therefore, the
wrinkles of the reinforcement fabric 14, which would have
occurred if the reinforcement fabric 14 is pressed simply from
above (see Figs. 4A and 4B), do not occur, as shown in the
side view of the lower diagram of Fig. 5.
{0038}
Next, a lamination method for the reinforcement fabric
laminating apparatus 1, shown in Figs. 1 and 2, will be
described.
The reinforcement fabric laminating apparatus 1 is
manually operated. The operator grips the grippers of the
handles 8 and moves the reinforcement fabric laminating
apparatus 1 so as to push it in the longitudinal direction of
the airfoil 15. The motor 9 is activated to rotationally
drive the pressure contact roller shaft 3b. Thus, as the
operator moves the reinforcement fabric laminating apparatus 1
so as to push it in the longitudinal direction of the airfoil
15, the pressure contact roller portion 3a rotates on the
airfoil 15. Thus, the reinforcement fabric laminating
apparatus 1 can move on the airfoil 15.
As the reinforcement fabric laminating apparatus 1 moves
on the airfoil 15, the roll shaft 2b rotates, so that the
reinforcement fabric 14 is fed out from the sheet roll 2a to
the pressure contact roller 3 while being subjected to
tension. The tension of the reinforcement fabric 14 fed out
from the sheet roll 2a to the pressure contact roller 3 is
generated due to frictional resistance during the rotation of
the roll shaft 2b. The frictional resistance during the
rotation of the roll shaft 2b is generated by omitting a
rolling bearing or the like that stabilizes the rotation at
the joint portions between the roll shaft 2b and the frames
13a and 13b and by employing a slide bearing that causes a
sliding frictional force.
When the sheet roll 2a rotates, an adhesive is sprayed by
the adhesive supply unit 7 onto the surface of the
reinforcement fabric 14 wound around the sheet roll 2a. The
central portion of the reinforcement fabric 14 that is fed out
from the sheet roll 2a is pressure-contacted and bonded to the
airfoil 15 by the pressure contact roller 3.
{0039}
As described above, the reinforcement fabric laminating
apparatus 1 according to this embodiment has the following
an additional mechanism for generating the tension.
Accordingly, because the reinforcement fabric 14 is fed out
onto the airfoil 15 while tension is generated therein with
the simple reinforcement fabric laminating apparatus 1 and is
pressure-contacted onto the airfoil 15 by the pressure contact
roller 3, the reinforcement fabric 14 can be laminated onto
the airfoil 15 with the simple reinforcement fabric laminating
apparatus 1 without being wrinkled.
{0041}
The reinforcement fabric 14 is fed out onto the airfoil
15 while being subjected to tension, with the central portion
pressure-contacted. The right and left (both sides) of the
reinforcement fabric 14 whose central portion is pressure-
contacted are therefore uniformly subjected to force. This
allows the right and left of the reinforcement fabric 14 whose
central portion is pressure-contacted to be laminated onto the
airfoil 15 without being wrinkled.
{0042}
The reinforcement fabric laminating apparatus 1 includes
the adhesive supply unit 7. The reinforcement fabric
laminating apparatus 1 can therefore perform bonding of the
reinforcement fabric 14 onto the airfoil 15, as well as
feeding, wrinkle smoothing, and pressure contacting. Thus,
the efficiency of the reinforcement fabric laminating
operation can be improved.
{0043}
Since the fiber direction of the reinforcement fabric 14
is aligned with the longitudinal direction of the airfoil 15,
when the reinforcement fabric 14 is pressure-contacted, the
pressure-contacted fiber 14d (see the upper diagram in Fig. 5)
does not extend in the longitudinal direction, but the fibers
14c and 14e around it (see the upper diagram in Fig. 5) are
not restricted in the longitudinal direction, and is displaced
in the longitudinal direction due to the tension and is thus
shifted.
{0044}
The reinforcement fabric laminating apparatus 1 is
provided with the pressure contact roller portion 3a and the
motor 9 that drives the pressure contact roller portion 3a and
can be moved under manual control by operating the handles 8.
The apparatus does not need a complicated control mechanism,
and the operation of laminating the reinforcement fabric 14
onto the airfoil 15 can be performed by the simple
reinforcement fabric laminating apparatus 1. This allows the
operation of laminating the reinforcement fabric 14 for
forming a wind turbine blade to be performed with a small
number of persons, as compared with the known manual
laminating operation, thus allowing reduction in labor costs
and improvement in operating efficiency.
{0045}
Although this embodiment has been described as applied to
the case where the tension of the reinforcement fabric 14 is
caused by the frictional resistance between the roll shaft 2b
and the frames 13a and 13b during rotation, the present
invention is not limited thereto; a mechanism for mechanically
controlling frictional resistance may be provided if strict
tension control is necessary.
Although this embodiment has been described as applied to
the case where the airfoil 15 for forming a wind turbine blade
is used as a mold, the present invention is not limited
thereto; any curved or bent mold may be used. Examples of a
reinforcement fabric laminated on such molds include glass
fibers and carbon fibers.
{0046}
{Second Embodiment}
A second embodiment of the present invention will be
described hereinbelow. The configuration of a reinforcement
fabric laminating apparatus and a laminating method of this
embodiment differ from the first embodiment in that auxiliary
pressure contact means is provided; the other features are the
same. Accordingly, the same configurations and laminating
method are given the same reference signs, and descriptions
thereof will be omitted.
{0047}
Fig. 6 shows that the reinforcement fabric laminating
apparatus 1 shown in Fig. 1 is provided with auxiliary
pressure contact units 4 and 5.
The auxiliary pressure contact rollers (auxiliary
pressure contact units) 4 and 5 are provided at a plurality of
(for example, two) locations. The auxiliary pressure contact
rollers 4 and 5 include auxiliary pressure contact roller
portions 4a and 5a and auxiliary pressure contact roller
shafts (not shown), respectively.
{0048}
Ends of the auxiliary pressure contact roller shafts are
connected to members 10 and 11 extending downwards from the
frames 13a and 13b, respectively. The members 10 and 11 are
provided with springs 10a and 11a, respectively.
The auxiliary pressure contact roller shafts connected to
the members 10 and 11 extending downwards from the frames 13a
and 13b pass through the centers of the auxiliary pressure
contact roller portions 4a and 5a, respectively. The
auxiliary pressure contact rollers 4 and 5 are provided at
both sides of the pressure contact roller 3 so as to be
equally spaced in a line in the widthwise direction of the
airfoil 15, with the pressure contact roller 3 therebetween.
The auxiliary pressure contact rollers 4 and 5 push the
reinforcement fabric 14 onto the aerofoil 15 so that the
reinforcement fabric 14 does not peel off from the top side
of the airfoil 15.
{0049}
The pressure with which the auxiliary pressure contact
rollers 4 and 5 push the reinforcement fabric 14 onto the
airfoil 15 need only press the reinforcement fabric 14 to
prevent it from rising and is set smaller than the pressure
contact force applied by the pressure contact roller 3 for
pushing and fixing the reinforcement fabric 14 onto the
airfoil 15. Specifically, the pressure can be adjusted with
the springs 10a and 11a provided in the members 10 and 11
extending downwards from the frames 13a and 13b.
{0050}
The reinforcement fabric laminating apparatus 1 pressure-
contacts the central portion of the reinforcement fabric 14 in
the longitudinal direction of the aerofoil 15 with the
pressure contact roller 3 and pushes fibers around the
contact-pressed fibers in the longitudinal direction of the
aerofoil 15 with the auxiliary pressure contact rollers 4 and
5 so as to prevent them from peeling off from the top side of
the airfoil 15.
{0051}
As described above, the reinforcement fabric laminating
apparatus 1 according to this embodiment provides the
following operational advantages.
The reinforcement fabric 14 is pushed onto the aerofoil
15 by the auxiliary pressure contact rollers 4 and 5.
Accordingly, this can prevent the reinforcement fabric 14 from
peeling off from the top side of the airfoil 15.
{0052}
Although this embodiment has been described as applied to
the case where the auxiliary pressure contact rollers 4 and 5
are provided in a line in the widthwise direction of the
airfoil 15, with the pressure contact roller 3 therebetween,
the present invention is not limited thereto; the auxiliary
pressure contact rollers 4 and 5 may also be provided below
the frames 13a and 13b so as to be parallel to the frames 13a
and 13b; they may be disposed to suit the shape of the mold or
the kind and shape of the fibers.
{0053}
{Third Embodiment}
A third embodiment of the present invention will be
described hereinbelow. The configuration of a reinforcement
fabric laminating apparatus and a laminating method of this
embodiment differ from the first embodiment in that a movable
unit is provided and that the movable unit is moved along the
longitudinal direction of the airfoil and are the same in the
others. Accordingly, the same configurations and laminating
method are given the same reference signs, and descriptions
thereof will be omitted.
{0054}
Fig. 7 shows that the reinforcement fabric laminating
apparatus 1 shown in Fig. 1 is provided with a movable unit
20, and the movable unit 20 moves on a rail 30 along the
longitudinal direction of the airfoil 15.
The arm means (movable unit) 20 includes a base 21 to
which an arm 22 is connected and the arm 22 equipped with the
sheet feeding mechanism 2 and the pressure contact roller 3.
The base 21 includes a base portion 21a, running rollers
21b, and a motor (not shown). The running rollers 21b rotate
on the rail 30, which is installed in a factory. The base
portion 21a is provided with the motor and a coupling portion
(not shown, hereinafter referred to as a first coupling
portion). The arm 22 is connected to the first coupling
portion of the base portion 21a. The first coupling portion
allows the arm 22 to move freely in the widthwise direction of
the airfoil 15. The motor provided at the base portion 21a is
a power source for moving the arm 22. The motor moves the arm
22 freely in the widthwise direction of the aerofoil 15 using
the first coupling portion and in the vertical direction
perpendicular to the longitudinal direction and the widthwise
direction of the airfoil 15 (in the vertical direction in Fig.
7) using a second coupling portion, described later.
{0055}
The arm 22 includes two members 22a and 22b and the
coupling portion (now shown, hereinafter referred to as a
second coupling portion). Ends of the members 22a and 22b are
reinforcement fabric 14 is pressure-contacted and bonded onto
the airfoil 15 by the roller 3. By moving the arm 22 with the
motor provided at the arm unit 20, the reinforcement fabric 14
and the pressure contact roller 3 can be moved to any position
on the airfoil 15 in the widthwise direction.
{0057}
As described above, the reinforcement fabric laminating
apparatus 1 according to this embodiment provides the
following operational advantages.
The sheet feeding mechanism 2 and the pressure contact
roller 3 can be freely moved in the longitudinal direction of
the airfoil 15 and in the vertical direction perpendicular to
the longitudinal direction and the widthwise direction of the
airfoil 15 (in the vertical direction in Fig. 7). This allows
the pressure contact roller 3 to be pressure-contacted onto
the airfoil 15 by moving the arm unit 20 even if the
reinforcement fabric 14 is laminated on the curved or bent
airfoil 15. Accordingly, the reinforcement fabric 14 can be
laminated on even the curved or bent airfoil 15 without the
pressure contact roller 3 being separated from the top side of
the airfoil 15.
Since the sheet feeding mechanism 2 and the pressure
contact roller 3 can be moved in the vertical direction
perpendicular to the longitudinal direction and the widthwise
direction of the airfoil 15 (in the vertical direction in Fig.
7) during replacement of the fiber-reinforced sheet roll and
maintenance of the sheet feeding mechanism 2 and the pressure
contact roller 3 by moving the arm unit 20, these operations
can be simplified.
Furthermore, since the sheet feeding mechanism 2 and the
pressure contact roller 3 can be continuously moved in the
longitudinal direction of the airfoil 15, the reinforcement
fabric 14 can easily be laminated on the large airfoil 15.
{0058}
While this embodiment has been described as applied to
the case where the reinforcement fabric laminating apparatus 1
is manually moved on the rail 30, the present invention is not
limited thereto; the reinforcement fabric laminating apparatus
1 may be moved on the rail 30 by driving means, such as a
motor.
While the arm 22 that cantilevers the sheet feeding
mechanism 2 and the pressure contact roller 3 has been
described, an additional frame may be provided to support the
central position of the pressure contact roller 3.
Furthermore, the pressure contact roller 3 may be
supported not only in a horizontal position but also in a
tilted position, depending on the shape of the airfoil 15,
thereby improving the workability.
{Reference Signs List}
{0059}
{CLAIMS}
{Claim 1}
A reinforcement fabric laminating apparatus comprising:
a sheet feeding unit that feeds out a reinforcement
fabric to be laminated on a mold; and
a pressure contact unit that pressure-contacts the
reinforcement fabric onto the mold,
wherein the pressure contact unit has a narrower width
than the reinforcement fabric, and
the sheet feeding unit supplies the reinforcement fabric
while applying tension between the sheet feeding unit and the
pressure contact unit.
{Claim 2}
The reinforcement fabric laminating apparatus according
to Claim 1, wherein the pressure contact unit pressure-
contacts the central portion of the reinforcement fabric.
{Claim 3}
The reinforcement fabric laminating apparatus according
to Claim 1 or 2, wherein the tension of the reinforcement
fabric fed out from the sheet feeding unit is generated due to
frictional resistance of the sheet feeding unit.
{Claim 4}
The reinforcement fabric laminating apparatus according
to any of Claims 1 to 3, wherein the sheet feeding unit
includes an adhesive supply unit that supplies an adhesive for
bonding the reinforcement fabric and the mold together.
{Claim 5}
The reinforcement fabric laminating apparatus according
to any of Claims 1 to 4, wherein
the mold is for forming a large fiber-reinforced plastic
product, such as a wind turbine blade, by laminating the
reinforcement fabric thereon;
the sheet feeding unit includes a handle; and
the pressure contact unit includes a pressure contact
roller and a driving unit that drives the pressure contact
roller.
{Claim 6}
The reinforcement fabric laminating apparatus according
to any of Claims 1 to 5, comprising an auxiliary pressure
contact unit that pushes the reinforcement fabric onto the
mold.
{Claim 7}
The reinforcement fabric laminating apparatus according
to any of Claims 1 to 6, comprising a movable unit to
which the sheet feeding unit and the pressure contact unit are
connected,
wherein the movable unit is moved along the longitudinal
direction of the mold and can freely move the sheet feeding
unit and the pressure contact unit in the widthwise direction
of the mold and in a vertical direction perpendicular to the
longitudinal direction and the widthwise direction of the
mold.
{Claim 8}
A laminating method for a reinforcement fabric laminating
apparatus having:
a sheet feeding unit that feeds out a reinforcement
fabric to be laminated on a mold; and
a pressure contact unit that pressure-contacts the
reinforcement fabric onto the mold,
wherein the pressure contact unit has a narrower width
than the reinforcement fabric, and
the sheet feeding unit supplies the reinforcement fabric
while applying tension between the sheet feeding unit and the
pressure contact unit.

ABSTRACT
Provided are a device and a method for laminating a reinforcement fiber base material, wherein, generation of a
crease can be prevented when the sheet-shaped reinforcement fiber base material is laminated onto a mold having a curved or bent
shape, labor load can be reduced, and operation can be made efficient. The reinforcement fiber base material lamination device (1)
comprises a sheet feeding unit for feeding a reinforcement fiber base material sheet (14) to be laminated on the mold (15), and a
pressure welding unit (3) for performing pressure welding of the reinforcement fiber base material sheet (14) onto the mold (15),
wherein the pressure welding unit (3) has a width narrower than the reinforcement fiber base material sheet (14), and the sheet
feeding unit feeds the reinforcement fiber base material sheet (14) to the pressure welding unit (3) while applying a load.