A wind power blade and a preparation method thereof

Abstract

The present invention relates to the technical field of wind turbine blades, and discloses a wind turbine blade and a preparation method thereof. The wind turbine blade is integrally formed by curing a modified epoxy resin gel coat system, a surface mat, a blade fabric ply, a core material, and a casting resin. The modified epoxy resin gel coat system contains an epoxy resin gel coat, molybdenum disulfide, and a toughening agent. The method includes: providing a modified epoxy resin gel coat system containing an epoxy resin gel coat, molybdenum disulfide, and a toughening agent; cleaning the mold and applying a release agent, then applying the modified epoxy resin gel coat system. After the modified epoxy resin gel coat system is cured, a surface mat, a blade fabric ply, and a core material are sequentially laid, then a release fabric, an isolation film, a flow guiding net, a bonding vacuum bag film, an inserted exhaust pipe, and a resin inlet pipe are laid. Then, a casting resin is injected by means of vacuum infusion, cured, and demolded. The present invention can improve the wear resistance and corrosion resistance of the wind turbine blade, and can avoid cracking on the blade surface.

Description

Technical Field

[0001] The present invention relates to the technical field of wind turbine blades, and particularly to a wind turbine blade and a preparation method thereof. More specifically, it relates to a wind turbine blade with a corrosion-resistant structure and a preparation method thereof. Background Art

[0002] Wind turbine units generally operate in relatively harsh environments. As the components for capturing wind energy, blades are most prone to corrosion due to long-term impacts from wind, sand particles, etc., especially at the leading edge of the blades. After corrosion, the aerodynamic shape of the blades will change, which will not only reduce the power generation, but in the long run, it will even cause more serious damage to the blades, affecting the lifespan of the blades and the safety of the units. Therefore, overall protection of the blades, especially the leading edge protection, is one of the important challenges in the development and application of blades.

[0003] Currently, in response to this situation, the existing commonly used methods include using protective coatings or pasting protective films, etc. mainly after the blades are produced, by means of brushing or film pasting. There are already various invented or actual leading edge protection paint products in the prior art, including polyurethane-modified, nano-ceramic, etc., mainly applied by brushing. Some products either have complex preparation processes or unsatisfactory effects after wind farm verification. The protective film has strict requirements for the construction process. Before film pasting, the surface needs to be polished and cleaned. If the intensity is not well controlled, it is easy to cause damage to the blade body. And there should be no tiny air bubbles during the film pasting process. The overall interface performance is not easy to control and it is easy to fall off. In addition, generally, the service life of the protective film is limited and needs to be replaced, resulting in high subsequent maintenance costs.

[0004] For example, patent application CN112592503A discloses a preparation method of a protective coating, which realizes the protection of the blade by using the prepared modified PVDF film. This method mainly has a complex method for pre-preparing the modified PVDF film and unsatisfactory practical operability.

[0005] Patent application CN215804937U discloses a leading edge protection system for wind turbine blades. This system realizes multiple protection of the leading edge by setting a flexible glass protection layer in the leading edge area of the wind turbine blade and relying on the characteristics of the flexible glass, or by setting an anti-ultraviolet coating on the outside. However, this method is very likely to fall off and the protection effect is not ideal.

[0006] The technical solutions of the above patent applications are all technical means for leading edge protection of blades, and they either have problems with poor practical operability or are extremely likely to fall off subsequently. Summary of the Invention

[0007] The purpose of the present invention is to overcome the problems of poor corrosion resistance and wear resistance existing in the existing wind turbine blades, and to provide a wind turbine blade with a corrosion-resistant structure and a preparation method thereof.

[0008] To achieve the above object, on the one hand, the present invention provides a wind turbine blade, which is integrally cured and formed from a modified epoxy resin gel coat system, a surface mat, a blade fabric ply, a core material, and an infusion resin. The modified epoxy resin gel coat system contains epoxy resin gel coat, molybdenum disulfide, and a toughening agent.

[0009] Preferably, based on the total weight of the modified epoxy resin gel coat system, the modified epoxy resin gel coat system contains 92-99.8% by weight of epoxy resin gel coat, 0.1-5% by weight of molybdenum disulfide, and 0.1-6% by weight of toughening agent.

[0010] More preferably, based on the total weight of the modified epoxy resin gel coat system, the modified epoxy resin gel coat system contains 92-97% by weight of epoxy resin gel coat, 1-3% by weight of molybdenum disulfide, and 2-5% by weight of toughening agent.

[0011] Preferably, in the modified epoxy resin gel coat system, molybdenum disulfide exists in the form of particles, and the average particle size is 300 mesh - 5000 mesh.

[0012] Preferably, the blade fabric ply is a glass fiber fabric and / or a carbon fiber fabric.

[0013] Preferably, the surface mat is a glass fiber surface mat.

[0014] Preferably, the toughening agent is one or any combination of at least two of polypropylene glycol diglycidyl ether, polybutylene glycol diglycidyl ether, and polyethylene glycol diglycidyl ether, and more preferably polybutylene glycol diglycidyl ether.

[0015] On the second aspect, the present invention provides a method for preparing the above wind turbine blade, which is characterized in that the method includes:

[0016] (1) Providing a modified epoxy resin gel coat system containing epoxy resin gel coat, molybdenum disulfide, and a toughening agent;

[0017] (2) Cleaning the mold, applying a release agent, raising the mold surface temperature to 40-50°C, then applying the modified epoxy resin gel coat system. After the modified epoxy resin gel coat system is cured, lay the surface mat, the blade fabric ply, and the core material in sequence, then lay the release cloth, the isolation film, the flow guiding net, the bonding vacuum bag film, the inserted exhaust pipe, and the resin inlet pipe, and then inject the infusion resin by vacuum infusion, cure, and demold.

[0018] Preferably, the coating thickness of the modified epoxy resin gel coat system is 75-150μm.

[0019] The third aspect of the present invention provides a wind power blade prepared by the above method.

[0020] For the wind power blade according to the present invention, by introducing molybdenum disulfide into the modified epoxy resin gel coat system, without reducing the performance of the epoxy resin gel coat, the corrosion resistance and wear resistance of the material can be significantly improved; moreover, by introducing a toughening agent (especially polybutylene glycol diglycidyl ether) into the modified epoxy resin gel coat system, not only will the overall viscosity of the system be reduced, the processability be improved, but also the flexibility, ductility and impact resistance can be improved, and the cracking on the blade surface can be reduced.

[0021] In addition, the wind power blade according to the present invention is integrally cured and formed, with simple operation, and problems such as peeling and cracking of the wear-resistant layer caused by film sticking will not occur. Specific Embodiments

[0022] The following will detail the specific embodiments of the present invention. It should be understood that the specific embodiments described herein are only for the purpose of illustrating and explaining the present invention, and are not used to limit the present invention.

[0023] In the ranges disclosed herein, the endpoints and any values are not limited to the exact ranges or values, and these ranges or values should be understood to include values close to these ranges or values. For numerical ranges, between the endpoint values of each range, between the endpoint values of each range and individual point values, and between individual point values, they can be combined with each other to obtain one or more new numerical ranges, and these numerical ranges should be regarded as specifically disclosed herein.

[0024] The wind power blade according to the present invention is integrally cured and formed from a modified epoxy resin gel coat system, a surface mat, a blade fabric ply, a core material, and a casting resin. Among them, the integral curing and forming can be implemented in a conventional manner in the art, for example, it can be implemented by means of mold casting. In the wind power blade, the surface mat, the blade fabric ply, and the core material are coated in the modified epoxy resin gel coat structure and the casting resin system.

[0025] In the present invention, the modified epoxy resin gel coat system contains an epoxy resin gel coat, molybdenum disulfide, and a toughening agent. Among them, the introduction of molybdenum disulfide can significantly improve the corrosion resistance and wear resistance of the wind power blade, and the introduction of the toughening agent (especially polybutylene glycol diglycidyl ether) not only reduces the overall viscosity of the system, improves the processability, but also can improve the flexibility, ductility and impact resistance, and reduce the cracking on the blade surface.

[0026] In the modified epoxy resin gel coat system, the contents of the molybdenum disulfide and the toughening agent can be selected within a relatively wide range. In a specific embodiment, based on the total weight of the modified epoxy resin gel coat system, the modified epoxy resin gel coat system contains 92-99.8% by weight of epoxy resin gel coat, 0.1-5% by weight of molybdenum disulfide, and 0.1-6% by weight of toughening agent. In a preferred case, based on the total weight of the modified epoxy resin gel coat system, the modified epoxy resin gel coat system contains 92-97% by weight of epoxy resin gel coat, 1-3% by weight of molybdenum disulfide, and 2-5% by weight of toughening agent. Most preferably, based on the total weight of the modified epoxy resin gel coat system, the modified epoxy resin gel coat system contains 93% by weight of epoxy resin gel coat, 2% by weight of molybdenum disulfide, and 5% by weight of toughening agent.

[0027] In the modified epoxy resin gel coat system, the toughening agent can be one or any combination of at least two of polypropylene glycol diglycidyl ether, polybutylene glycol diglycidyl ether, and polyethylene glycol diglycidyl ether, and most preferably is polybutylene glycol diglycidyl ether.

[0028] In the modified epoxy resin gel coat system, the epoxy resin gel coat can be a conventional epoxy resin gel coat for wind turbine blades in the art. For example, it can be an epoxy resin gel coat product purchased from Mechwage Co., Ltd., with the product number Seevenax gelcoat 132-18 / Seevenax hatter 135-18 (wherein, one is the main agent and the other is the curing agent, and the two are used in combination).

[0029] In the modified epoxy resin gel coat system, preferably, the molybdenum disulfide exists in the form of particles. The average particle size of the molybdenum disulfide particles can be 300-5000 mesh, preferably 300-1000 mesh.

[0030] In the wind turbine blade of the present invention, the blade fabric ply can be a conventional selection in the art. For example, it can be a glass fiber fabric and / or a carbon fiber fabric, and most preferably is a glass fiber fabric.

[0031] In the wind turbine blade of the present invention, the surface mat can be a conventional selection in the art. In a more preferred embodiment, in order to further improve the comprehensive performance (such as corrosion resistance, wear resistance, mechanical properties, etc.) of the wind turbine blade, the surface mat is a glass fiber surface mat, and more preferably is a 30 g / m 2 glass fiber surface mat.

[0032] In the wind turbine blade of the present invention, the infusion resin can be a conventional epoxy resin system for infusion molding of wind turbine blades in the art.

[0033] In the wind power blade of the present invention, the core material can be a conventional core material in the art for forming a wind power blade.

[0034] In the present invention, the method for preparing the wind power blade may include the following steps:

[0035] (1) Provide a modified epoxy resin gel coat system containing epoxy resin gel coat, molybdenum disulfide and toughening agent;

[0036] (2) Clean the mold, apply a mold release agent, raise the mold surface temperature to 40 - 50 °C, then apply the modified epoxy resin gel coat system. After the modified epoxy resin gel coat system cures, lay a surface mat, a blade fabric ply and a core material in sequence, then lay a release cloth, an isolation film, a flow guiding net, a bonding vacuum bag film, an inserted air extraction pipe and a resin inlet pipe, and then inject a casting resin by vacuum infusion, cure, and demold.

[0037] In step (1), the specific process of providing the modified epoxy resin gel coat system is as follows: Weigh a certain amount of toughening agent, then add a certain amount of molybdenum disulfide powder, conduct physical stirring for 10 - 30 minutes, then weigh a certain amount of epoxy resin gel coat, and then stir and mix it evenly with the toughening agent containing molybdenum disulfide powder. In a more preferred embodiment, the stirring and mixing process is to use a disperser and conduct physical stirring under ultrasonic waves. The stirring and mixing time can be 5 - 30 minutes.

[0038] In step (2), the coating thickness of the modified epoxy resin gel coat system can be 75 - 150 μm.

[0039] The present invention also provides a wind power blade prepared by the above method. The wind power blade not only does not have the problem of the wear-resistant layer peeling off caused by film sticking, but also has significantly improved corrosion resistance, wear resistance and toughness.

[0040] The wind power blade and its preparation method of the present invention will be further described below through examples. The examples are implemented on the premise of the technical solution of the present invention, and detailed implementation manners and specific operation processes are given, but the protection scope of the present invention is not limited to the following examples.

[0041] In the following examples, the experimental methods, unless otherwise specified, are all conventional methods in the art. The experimental materials used in the following examples, unless otherwise specified, can all be commercially obtained.

[0042] The sources of the commodities used in the following examples and comparative examples are as follows:

[0043] The epoxy resin gel coat is purchased from Meikaiweiqi Company, with the product numbers Seevenax gelcoat 132 - 18 / Seevenaxhatter 135 - 18;

[0044] The average particle size of the molybdenum disulfide powder is 300 mesh, and it is purchased from Tianjin Yuandong Chemical Co., Ltd.

[0045] The fiberglass surface mat (30 g / m 2 ) is purchased from Aerospace Ruite Co., Ltd., with the grade 2AX-800.

[0046] The fiberglass fabric is purchased from Aerospace Ruite Co., Ltd., with the grade 3AX-1215.

[0047] The casting resin is purchased from Tianjin Shangwei Co., Ltd., with the grade 2511-1A / BS.

[0048] Example 1

[0049] This example is used to illustrate the wind turbine blade and its preparation method according to the present invention.

[0050] (1) Weigh 93 parts by weight of epoxy resin gel coat, 2 parts by weight of molybdenum disulfide powder, and 5 parts by weight of polybutylene glycol diglycidyl ether. First, add the molybdenum disulfide powder to the polybutylene glycol diglycidyl ether and mix evenly by stirring, then add the obtained mixture to the epoxy resin gel coat system and stir evenly again to obtain the modified epoxy resin gel coat system A1.

[0051] (2) Clean the mold, apply a release agent, the mold surface temperature is 45°C, then apply the modified epoxy resin gel coat system A1 with a coating thickness of 120 μm. Within 2 hours after the gel coat system cures, lay the surface mat, the blade fabric ply, and the core material in sequence, then lay the release cloth, the isolation film, the flow guiding net, the bonding vacuum bag film, the inserted exhaust pipe, and the resin inlet pipe, and then inject the casting resin by vacuum infusion, cure, and demold to obtain the wind turbine blade S1.

[0052] Example 2

[0053] This example is used to illustrate the wind turbine blade and its preparation method according to the present invention.

[0054] (1) Weigh 95 parts by weight of epoxy resin gel coat, 1 part by weight of molybdenum disulfide powder, and 4 parts by weight of polybutylene glycol diglycidyl ether. First, add the molybdenum disulfide powder to the polybutylene glycol diglycidyl ether and mix evenly by stirring, then add the obtained mixture to the epoxy resin gel coat system and stir evenly again to obtain the modified epoxy resin gel coat system A2.

[0055] (2) Clean the mold, apply the mold release agent, with the mold surface temperature at 40 °C, then apply the modified epoxy resin gel coat system A2 with a coating thickness of 75 μm. Within 2 hours after the gel coat system cures, lay the surface mat, blade fabric ply, and core material in sequence, then lay the release cloth, isolation film, flow guiding net, bonding vacuum bag film, insert the exhaust pipe and the resin inlet pipe, and then inject the casting resin by vacuum infusion, cure, and demold to obtain the wind turbine blade S2.

[0056] Example 3

[0057] This example is used to illustrate the wind turbine blade and its preparation method according to the present invention.

[0058] (1) Weigh 92 parts by weight of epoxy resin gel coat, 3 parts by weight of molybdenum disulfide powder, and 5 parts by weight of polybutylene glycol diglycidyl ether. First, add the molybdenum disulfide powder to the polybutylene glycol diglycidyl ether and mix evenly by stirring, then add the obtained mixture to the epoxy resin gel coat system and stir evenly again to obtain the modified epoxy resin gel coat system A3.

[0059] (2) Clean the mold, apply the mold release agent, with the mold surface temperature at 50 °C, then apply the modified epoxy resin gel coat system A3 with a coating thickness of 150 μm. Within 2 hours after the gel coat system cures, lay the surface mat, blade fabric ply, and core material in sequence, then lay the release cloth, isolation film, flow guiding net, bonding vacuum bag film, insert the exhaust pipe and the resin inlet pipe, and then inject the casting resin by vacuum infusion, cure, and demold to obtain the wind turbine blade S3.

[0060] Comparative Example 1

[0061] Prepare the wind turbine blade according to the method of Example 1, except that in step (1), no molybdenum disulfide powder is added, thus obtaining the wind turbine blade D1.

[0062] Comparative Example 2

[0063] Prepare the wind turbine blade according to the method of Example 1, except that in step (1), no molybdenum disulfide powder and polybutylene glycol diglycidyl ether are added, thus obtaining the wind turbine blade D3.

[0064] Test Example

[0065] Detect the abrasion resistance of the wind turbine blades prepared in the above examples and comparative examples according to the ASTM D4060 method, and the results are shown in Table 1 below.

[0066] Detect the corrosion resistance of the wind turbine blades prepared in the above examples and comparative examples according to the ASTM G78 method, and the results are shown in Table 1 below.

[0067] Table 1

[0068] Example No. Wear resistance (mg) <![CDATA[Corrosion resistance (mm 3 / g)]]> Example 1 137 0.095 Example 2 139 0.096 Example 3 135 0.095 Comparative Example 1 149 0.098 Comparative Example 2 150 0.100

[0069] As can be seen from the results in Table 1, according to the technical solution of the present invention, the wear resistance and corrosion resistance of the wind turbine blade can be improved, and cracking on the blade surface can be avoided.

[0070] The preferred embodiments of the present invention have been described in detail above. However, the present invention is not limited thereto. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, including any other suitable combination of each technical feature. These simple modifications and combinations should also be regarded as the content disclosed by the present invention and fall within the protection scope of the present invention.

Claims

1. A wind power blade, characterized in that, the wind power blade is integrally cured and formed from a modified epoxy resin gel coat system, a surface mat, a blade fabric ply, a core material, and an infusion resin. The modified epoxy resin gel coat system contains epoxy resin gel coat, molybdenum disulfide, and a toughening agent. Based on the total weight of the modified epoxy resin gel coat system, the modified epoxy resin gel coat system contains 92 - 99.8 wt% of epoxy resin gel coat, 0.1 - 5 wt% of molybdenum disulfide, and 0.1 - 6 wt% of toughening agent.

2. The wind power blade according to claim 1, characterized in that, based on the total weight of the modified epoxy resin gel coat system, the modified epoxy resin gel coat system contains 92 - 97 wt% of epoxy resin gel coat, 1 - 3 wt% of molybdenum disulfide, and 2 - 5 wt% of toughening agent.

3. The wind power blade according to claim 1 or 2, characterized in that, in the modified epoxy resin gel coat system, molybdenum disulfide exists in the form of particles, and the average particle size is 300 mesh - 5000 mesh.

4. The wind power blade according to claim 1 or 2, characterized in that, the blade fabric ply is a glass fiber fabric and / or a carbon fiber fabric.

5. The wind power blade according to claim 1 or 2, characterized in that, the surface mat is a glass fiber surface mat.

6. The wind power blade according to claim 1 or 2, characterized in that, the toughening agent is one or any combination of at least two of polypropylene glycol diglycidyl ether, polybutylene glycol diglycidyl ether, and polyethylene glycol diglycidyl ether.

7. The wind power blade according to claim 6, characterized in that, the toughening agent is polybutylene glycol diglycidyl ether.

8. A method for preparing the wind power blade according to any one of claims 1 - 7, characterized in that, the method comprises: (1) providing a modified epoxy resin gel coat system containing epoxy resin gel coat, molybdenum disulfide, and a toughening agent; (2) cleaning the mold, applying a release agent, raising the mold surface temperature to 40 - 50 °C, then applying the modified epoxy resin gel coat system. After the modified epoxy resin gel coat system is cured, sequentially lay the surface mat, the blade fabric ply, and the core material, then lay the release cloth, the isolation film, the flow guide net, bond the vacuum bag film, insert the air extraction pipe and the resin inlet pipe, and then inject the infusion resin by vacuum infusion, cure, and demold.

9. The method according to claim 8, characterized in that, the coating thickness of the modified epoxy resin gel coat system is 75 - 150 μm.

10. A wind power blade prepared by the method according to claim 8 or 9.