A blade with a lightning protection system and its molding method

Abstract

The present application provides a blade with a lightning protection system and a forming method thereof. The blade with the lightning protection system includes a blade body, a lead-down structure, and a lightning receiving component. The lead-down structure is attached to the surface of the blade body. The lightning receiving component includes a first lightning receiving member and a second lightning receiving member which are spaced apart. The first lightning receiving member is connected to the lead-down structure and exposed on the surface of the blade body. The second lightning receiving member is disposed at the tip of the blade body and connected to the lead-down structure through a conductive member. In the above structure, since the lead-down structure is attached to the surface of the blade body, the structural change of the blade body caused by the setting of the lightning receiving component and the lead-down structure is reduced, so that the structural integrity of the blade with the lightning protection system is better, which is beneficial to improving the reliability of the quality of the blade with the lightning protection system.

Description

Technical Field

[0001] The present application relates to the technical field of wind power generation, and particularly relates to a blade with a lightning protection system and a molding method thereof. Background Art

[0002] With the increasing attention of people to the environment, clean energy has received more and more attention. As a clean energy source, wind energy has attracted particular attention. In order to make full use of wind energy, wind turbines are more and more widely used.

[0003] Since wind turbines are mostly devices with relatively high heights, and the outer edge of the blade is usually located at a relatively high position, a lightning protection system needs to be provided on the blade. However, in the related art, due to the relatively special structure of the blade with a lightning protection system, its structure not only has poor integrity, but also the processing and molding process is relatively complex and the molding efficiency is relatively low. Summary of the Invention

[0004] In view of the above problems, the present application provides a blade with a lightning protection system and a molding method thereof. The blade with a lightning protection system has good integrity and relatively reliable quality.

[0005] In a first aspect, the present application provides a blade with a lightning protection system. The blade with a lightning protection system includes a blade body, a downlead structure, and a second lightning arrester. The downlead structure is attached to the surface of the blade body. The downlead structure includes a main body part and a first lightning arrester that are connected to each other. The first lightning arrester protrudes from the surface of the blade body. The second lightning arrester is arranged at the tip of the blade body and is connected to the downlead structure through a conductive member.

[0006] In a second aspect, the present application further provides a molding method of a blade with a lightning protection system. The molding method of the blade with a lightning protection system is used to mold the blade with a lightning protection system provided by the above technical solution. The molding method of the blade with a lightning protection system includes:

[0007] Providing a blade body, the blade body being provided with a downlead structure;

[0008] Setting a second lightning arrester, arranging the second lightning arrester at the tip of the blade body and connecting the second lightning arrester to the downlead structure through a conductive member.

[0009] According to the molding method of the blade with a lightning protection system provided by some embodiments of the present application, the step of providing the blade includes:

[0010] Providing a mold, the inner wall of the mold being provided with a groove,

[0011] Setting a downlead structure, arranging the first lightning arrester in the groove and laying the main body part on the inner wall with the groove;

[0012] Set the skin material, set the skin material in the mold, and the skin material covers the main body;

[0013] Pour thermoplastic resin into the mold.

[0014] According to the forming method of the blade with a lightning protection system provided by some embodiments of the present application, before the step of setting the skin material, it further includes:

[0015] Bond the downlead structure to the inner wall.

[0016] In a third aspect, the present application also provides a forming method of a blade with a lightning protection system. The forming method of the blade with a lightning protection system is used to form the blade with a lightning protection system provided by the above technical solution. The forming method of the blade with a lightning protection system includes:

[0017] Provide a blade body, and the blade body includes thermoplastic resin;

[0018] Set the downlead structure and the second lightning receiving element, lay the downlead structure and the second lightning receiving element on the blade body, and the downlead structure and the second lightning receiving element are electrically connected;

[0019] Heat the downlead structure to melt the blade body with the downlead structure by heating the downlead structure, and the molten thermoplastic resin adheres to the downlead structure.

[0020] According to the forming method of the blade with a lightning protection system provided by some embodiments of the present application, before the step of heating the downlead structure, it further includes:

[0021] Set the thermoplastic prepreg and cover at least part of the downlead structure with the thermoplastic prepreg.

[0022] According to the forming method of the blade with a lightning protection system provided by some embodiments of the present application, the step of heating the downlead structure includes:

[0023] Electrify the downlead structure to make it generate heat, so as to melt the thermoplastic prepreg and the blade body with the downlead structure, and both the molten thermoplastic resin and the blade body adhere to the downlead structure.

[0024] According to the forming method of the blade with a lightning protection system provided by some embodiments of the present application, the step of setting the downlead structure and the second lightning receiving element includes:

[0025] Lay the downlead structure at a preset position on the surface of the blade body, lay the second lightning receiving element at the tip of the blade body, and electrically connect the downlead structure and the second lightning receiving element.

[0026] According to the forming method of a blade with a lightning protection system provided by some embodiments of the present application, before the step of heating the down-lead structure, it further includes:

[0027] Pressurize the down-lead structure and press the down-lead structure against the blade body with a preset pressure.

[0028] According to the forming method of a blade with a lightning protection system provided by some embodiments of the present application, before the step of heating the down-lead structure, it further includes:

[0029] Vacuum treatment, vacuum the blade body and the down-lead structure.

[0030] The technical solutions provided by the embodiments of the present disclosure at least bring the following beneficial effects:

[0031] The present application provides a blade with a lightning protection system. The blade with a lightning protection system includes a blade body, a down-lead structure, and a lightning receiving component. The down-lead structure is attached to the surface of the blade body. The lightning receiving component includes a first lightning receiving member and a second lightning receiving member arranged separately. The first lightning receiving member is connected to the down-lead structure and exposed on the surface of the blade body. The second lightning receiving member is arranged at the tip of the blade body and is connected to the down-lead structure through a conductive member. In the above structure, since the down-lead structure is attached to the surface of the blade body, the structural change of the blade body caused by the arrangement of the lightning receiving component and the down-lead structure is reduced, so that the structural integrity of the blade with a lightning protection system is better, which is beneficial to improving the reliability of the quality of the blade with a lightning protection system. Since the second lightning receiving member arranged at the tip of the blade body is electrically connected to the down-lead structure through a conductive member, the structural change of the blade body caused by the arrangement of the lightning receiving member is reduced, so that the structural integrity of the blade with a lightning protection system is better, which is beneficial to improving the reliability of the quality of the blade with a lightning protection system.

[0032] The present application also provides a forming method of a blade with a lightning protection system. Since the blade body and the down-lead structure are integrally formed in the forming method of the blade with a lightning protection system, and the second lightning receiving member is directly installed at the tip of the integrally formed structure and electrically connected to the down-lead structure, the arrangement of the down-lead structure and the second lightning receiving member is efficient, which is beneficial to improving the forming efficiency of the blade with a lightning protection system.

[0033] The present application also provides another forming method of a blade with a lightning protection system. Since the blade body is secondarily melted and connected to the down-lead structure in the forming method of the blade with a lightning protection system, the connection time between the down-lead structure and the blade body is shortened, which is beneficial to reducing the forming time of the blade with a lightning protection system and improving the forming efficiency of the blade with a lightning protection system.

[0034] The above description is only an overview of the technical solution of this application. In order to understand the technical means of this application more clearly, it can be implemented according to the content of the specification. And in order to make the above and other purposes, features and advantages of this application more obvious and understandable, the following specifically illustrates the specific implementation manners of this application. Description of the Drawings

[0035] By reading the following detailed description of the preferred embodiments, various other advantages and benefits will become clear to those of ordinary skill in the art. The drawings are only for the purpose of showing the preferred embodiments and are not considered to be a limitation of this application. Moreover, throughout the drawings, the same reference numerals are used to represent the same components. In the drawings:

[0036] Figure 1 is a schematic structural diagram of a blade with a lightning protection system provided by some embodiments of this application;

[0037] Figure 2 is a schematic structural diagram of another blade with a lightning protection system provided by some embodiments of this application;

[0038] Figure 3 is a schematic partial internal structural diagram of a blade with a lightning protection system provided by some embodiments of this application;

[0039] Figure 4 is a flowchart of a forming method of a blade with a lightning protection system provided by some embodiments of this application;

[0040] Figure 5 is a flowchart of the step of providing a blade body in a forming method of a blade with a lightning protection system provided by some embodiments of this application;

[0041] Figure 6 is a flowchart of a forming method of another blade with a lightning protection system provided by some embodiments of this application;

[0042] Figure 7 is a schematic diagram of the arrangement position of a down-lead structure in a forming method of another blade with a lightning protection system provided by some embodiments of this application.

[0043] The reference numerals in the specific embodiments are as follows:

[0044] 1. Blade body; 2. Down-lead structure; 3. Lightning receiving assembly; 31. First lightning receiver; 32. Second lightning receiver; 4. Thermoplastic prepreg. Specific Embodiments

[0045] The embodiments of the technical solutions of the present application will be described in detail below with reference to the accompanying drawings. The following embodiments are only used to illustrate the technical solutions of the present application more clearly, and therefore are only examples and cannot be used to limit the protection scope of the present application.

[0046] It should be noted that, unless otherwise specified, the technical terms or scientific terms used in the embodiments of the present application should have the ordinary meanings understood by those skilled in the art to which the embodiments of the present application belong.

[0047] In the description of the embodiments of the present application, the orientation or positional relationship indicated by technical terms such as "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the embodiments of the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation to the embodiments of the present application.

[0048] In addition, technical terms such as "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. In the description of the embodiments of the present application, "a plurality of" means more than two, unless otherwise specifically defined.

[0049] In the description of the embodiments of the present application, unless otherwise clearly specified and limited, technical terms such as "installation", "connection", "connection", "fixation", etc. should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or integrated; it can also be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the embodiments of the present application can be understood according to specific situations.

[0050] In the description of the embodiments of the present application, unless otherwise clearly specified and limited, the first feature being "on" or "under" the second feature can be that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, the first feature being "above", "over" and "on" the second feature can be that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is at a higher horizontal height than the second feature. The first feature being "under", "beneath" and "under" the second feature can be that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is at a lower horizontal height than the second feature.

[0051] As people's attention to the environment continues to increase, clean energy has received more and more attention. As a kind of clean energy, wind energy has attracted particular attention. In order to make full use of wind energy, wind turbines are more and more widely used.

[0052] Since wind turbines are mostly devices with relatively high heights, lightning protection of wind turbines has always been concerned by technicians in this field, and lightning protection systems are usually required to be set on the blades at the highest positions of wind turbines. However, in related technologies, due to the setting of the lightning protection system, the structure of the blade will be changed, not only making the integrity of the blade poor, but also having a low processing and forming efficiency.

[0053] In order to improve the integrity of the blade with a lightning protection system, some embodiments of the present application provide a blade with a lightning protection system. The blade with a lightning protection system includes a blade body, a lead-down structure and a lightning receiving assembly. The lead-down structure is attached to the surface of the blade body. The lightning receiving assembly includes a first lightning receiving member and a second lightning receiving member which are arranged separately. The first lightning receiving member is connected to the lead-down structure and exposed on the surface of the blade body. The second lightning receiving member is arranged at the tip of the blade body and connected to the lead-down structure through a conductive member. In the above structure, since the lead-down structure is attached to the surface of the blade body, the structural change of the blade body caused by setting the lightning receiving assembly and the lead-down structure is reduced, so that the structural integrity of the blade with a lightning protection system is better, which is beneficial to improving the reliability of the quality of the blade with a lightning protection system.

[0054] The following further describes the blade with a lightning protection system and its forming method provided by specific embodiments of the present application in conjunction with the drawings and through specific implementation manners.

[0055] Some embodiments of the present application provide a blade with a lightning protection system, as Figure 1 and Figure 2 shown. The blade with a lightning protection system includes a blade body 1, a lead-down structure 2 and a lightning receiving assembly 3. The lead-down structure 2 is attached to the surface of the blade body 1. The lightning receiving assembly 3 includes a first lightning receiving member 31 and a second lightning receiving member 32 which are arranged separately. The first lightning receiving member 31 is connected to the lead-down structure 2 and exposed on the surface of the blade body 1. The second lightning receiving member 32 is arranged at the tip of the blade body 1 and connected to the lead-down structure 2 through a conductive member.

[0056] The blade body 1 may refer to the main structure in the blade with a lightning protection system, and it may include structures such as a main beam, a skin, and a web that are connected to each other.

[0057] The down-lead structure 2 can be a conductor that leads the lightning current received by the lightning protection component 3 to the grounding device. It is attached to the surface of the blade body 1 and extends along the direction from the blade tip to the blade root. The down-lead structure 2 can extend along the direction from the blade tip to the blade root and is used to guide the lightning current. The first lightning protection component 31 can be connected to the down-lead structure 2 and extend away from the blade body 1 from the down-lead structure 2, so that the first lightning protection component 31 is configured to be exposed from the surface of the blade body 1, enabling the first lightning protection component 31 to receive lightning strikes and lead the lightning current to the down-lead structure 2.

[0058] In some embodiments, the down-lead structures 2 are provided on both the windward side and the leeward side of the blade body 1, so that the down-lead structures 2 can form a Faraday cage to protect the whole blade. Exemplarily, the down-lead structures 2 can be distributed in a strip, band or mesh shape on the surface of the blade body 1, and those skilled in the art can set them according to the actual situation to smoothly drain the lightning current.

[0059] In some embodiments, the down-lead structure 2 can be provided on the surface of the blade body 1 or under the surface protection layer of the blade body 1, and those skilled in the art can set it according to the actual situation.

[0060] Exemplarily, the down-lead structure 2 can be made of metals such as copper and aluminum, or alloy materials such as aluminum alloy, or a mixed material of metal and composite material, or made of conductive fiber material. Those skilled in the art can select the material of the down-lead structure 2 according to the actual situation to make the down-lead structure 2 have strong conductivity.

[0061] The second lightning protection component 32 can be a device for directly receiving lightning strikes. It is connected to the down-lead structure 2 so that the received lightning current can be conducted to the down-lead structure 2 for smooth discharge. By arranging the second lightning protection component 32 at the blade tip of the blade body 1, the blade tip, which is often at the highest position of the entire wind turbine generator set, can use the second lightning protection component 32 to receive lightning strikes, which is beneficial to reducing the possibility of other parts of the wind turbine generator set being struck by lightning.

[0062] In some embodiments, the second lightning protection component 32 can be a sleeve-type second lightning protection component 32, so that the second lightning protection component 32 can be conveniently sleeved on the blade tip of the blade body 1, making the connection of the second lightning protection component 32 convenient. Exemplarily, the second lightning protection component 32 can be made of metals such as copper and aluminum, so that the second lightning protection component 32 has strong conductivity and can better attract lightning.

[0063] The conductive component can be a connecting piece made of metal material or other materials with conductivity. Exemplarily, the conductive component can be a copper connecting rivet. The conductive component can firmly connect the down-lead structure 2 and the second lightning protection component 32 while smoothly conducting electricity.

[0064] In the above structure, since the down-lead structure 2 is attached to the surface of the blade body 1, the structural change of the blade body 1 caused by the installation of the lightning receiving component 3 and the down-lead structure 2 is reduced, so that the structural integrity of the blade with the lightning protection system is better, which is beneficial to improving the reliability of the quality of the blade with the lightning protection system.

[0065] Some embodiments of the present application also provide a forming method for a blade with a lightning protection system. The forming method for the blade with a lightning protection system is used to form the blade with the lightning protection system provided by the above technical solution, such as Figure 4 shown, the forming method for the blade with the lightning protection system includes the following steps:

[0066] S1. Provide a blade body 1, and the blade body 1 is provided with a down-lead structure 2.

[0067] Through the above step S1, the blade body 1 with the down-lead structure 2 is provided, which is convenient for the second lightning receiving part 32 to be directly connected to the down-lead structure 2 when the second lightning receiving part 32 is arranged on the blade body 1 later, which is beneficial to simplifying the forming method of the blade with the lightning protection system and improving the forming efficiency of the blade.

[0068] In some embodiments, such as Figure 5 shown, the above step S1 may further include the following steps:

[0069] S11. Provide a mold, and the inner wall of the mold is provided with a groove.

[0070] The mold provided in the above step S11 may be a mold structure for forming a blade with a lightning protection system. By injecting the material for forming the blade with the lightning protection system into the mold, the material for forming the blade with the lightning protection system can be restricted in the mold to form a blade with a lightning protection system having a preset shape and structure.

[0071] The groove may be a recessed structure provided on the inner wall of the mold. By providing a groove recessed into the wall body on the inner wall of the mold, the blade with the lightning protection system can form a preset structure through the groove.

[0072] S12. Set the down-lead structure 2 and the first lightning receiving part 31, place the first lightning receiving part 31 in the groove, and lay the down-lead structure 2 on the inner wall with the groove.

[0073] In the above step S12, by placing the first lightning receiving part 31 in the groove and laying the down-lead structure 2 of the down-lead structure 2 on the inner wall surface with the groove, when the down-lead structure 2 is formed in the blade with the lightning protection system, the first lightning receiving part 31 protrudes from the down-lead structure 2 and protrudes from the surface of the blade body 1.

[0074] In some embodiments, a mold release agent can be evenly applied to the inner wall surface of the mold before the downlead structure 2 is arranged in the mold, so as to facilitate the subsequent removal of the blade with the lightning protection system from the mold.

[0075] In some embodiments, the forming method of the blade with the lightning protection system may further include the following steps:

[0076] S13. Bond the downlead structure 2 and bond the downlead structure 2 to the inner wall.

[0077] In the above step S13, by bonding the downlead structure 2 to the inner wall of the mold, the downlead structure 2 is fixed, reducing the possibility of the downlead structure 2 falling off the inner wall during subsequent operations and reducing the impact on the downlead structure 2 caused by subsequent operations.

[0078] In some embodiments, the forming method of the blade with the lightning protection system may further include the following steps:

[0079] S14. Set the skin material, set the skin material in the mold, and the skin material covers the downlead structure 2.

[0080] Through the above step S14, the skin material is set on the inner wall surface of the mold so that the skin material covers the downlead structure 2, so that the downlead structure 2 of the downlead structure 2 is formed on the skin surface of the blade with the lightning protection system formed by the skin material.

[0081] The skin material may include a fiber layer and a core material. In step S14, it may be to first lay the fiber layer at a preset position on the inner wall surface of the mold, the fiber layer covers the downlead structure 2, and then arrange the core material at a preset position on the fiber layer.

[0082] In some embodiments, the skin material may further include prefabricated structural components such as prefabricated tiles, prefabricated main beams, prefabricated auxiliary beams, and prefabricated trailing edge beams, so that these prefabricated structural components are integrally formed in the blade with the lightning protection system.

[0083] Exemplarily, the fiber layer may include but is not limited to other reinforcing fibers that meet the requirements of structural mechanical properties such as glass fiber, carbon fiber, or basalt fiber; the core material may include but is not limited to materials such as balsa wood, foam, and honeycomb core.

[0084] In some embodiments, the forming method of the blade with the lightning protection system further includes the following steps:

[0085] S15. Set the perfusion auxiliary material to form a diversion structure and a negative pressure environment.

[0086] Through the above step S15, a guide structure and a negative pressure environment are formed in the mold, so that the thermoplastic resin subsequently poured into the mold can be better filled into the mold cavity and infiltrate the skin material.

[0087] Pouring auxiliary materials may include demoulding cloth, porous membrane, guide net, resin introduction system (injection port, injection tube, valve, clamp and other components), exhaust system (breathing cotton, spiral tube, exhaust bag and other components), etc. By reasonably setting and installing the pouring auxiliary materials, a guide structure and a negative pressure environment can be formed in the mold cavity.

[0088] In some embodiments, after the injection auxiliary material is set, it is also possible to detect whether the negative pressure environment meets the requirements. For example, if the air pressure in the mold cavity is maintained within a range of 80% to 95% of the atmospheric pressure within a preset time range, it can be confirmed that the negative pressure environment in the mold cavity meets the requirements.

[0089] In some embodiments, the method for forming a blade with a lightning protection system further includes the following steps:

[0090] S16, pouring thermoplastic resin: pouring thermoplastic resin into the mold.

[0091] Through the above step S16, thermoplastic resin is poured into the mold to completely infiltrate the skin material and the downconductor structure 2 with the thermoplastic resin, so that the skin material and the downconductor structure 2 can be integrally formed into a whole structure after the thermoplastic resin is subsequently cured.

[0092] Illustratively, the thermoplastic resins provided in the embodiments of the present application include, but are not limited to, polymethyl methacrylate, polybutylene terephthalate, polyethylene, polyvinyl chloride, polystyrene, polyamide, polyformaldehyde, polycarbonate, polyphenylene ether, polysulfone, and rubber. Those skilled in the art can select the type of thermoplastic resin according to actual conditions so that the thermoplastic resin has the properties of softening when heated and hardening when cooled, and has good mechanical properties after curing.

[0093] S17, curing the thermoplastic resin.

[0094] Through the above step S17, the thermoplastic resin is solidified to form a blade with a lightning protection system having good mechanical properties.

[0095] In some embodiments, after curing for a preset time according to the curing system, a hardness tester can be used to detect the hardness of a preset position of the blade with the lightning protection system, and the curing can be judged to be completed when the hardness meets the design requirements.

[0096] In some embodiments, the method for forming a blade with a lightning protection system further includes the following steps:

[0097] S18. Trim the blade body 1 and trim the connection area of the blade body 1.

[0098] Through the above step S18, trim the flange edge of the blade body 1 so that the flange edge of the blade body 1 is relatively flat, facilitating the firm connection of different modules of the blade body 1 through the flange.

[0099] In some embodiments, the forming method of the blade with a lightning protection system further includes the following steps:

[0100] S2. Close the mold and connect different modules of the blade body 1.

[0101] Through the above step S2, different modules of the blade body 1 can be connected to form the blade body 1 with an integral structure.

[0102] In some embodiments, an adhesive substance can be set on the skin connection area of the corrected blade body 1 module, and pressure is applied to cure the adhesive substance, so that different modules of the blade body 1 can be firmly connected to form the integral structure of the blade body 1.

[0103] S3. Set the second lightning receptor 32, set the second lightning receptor 32 at the tip of the blade body 1 and connect the second lightning receptor 32 to the down-lead structure 2 through a conductive member.

[0104] Through the above step S3, the second lightning receptor 32 is sleeved on the tip of the blade body 1, so that the lightning arrester can be installed on the outer surface of the tip. The conductive member can be a copper connecting rivet. The second lightning receptor 32 connected to the tip is connected to the down-lead structure 2 through the conductive member, which not only makes the connection of the second lightning receptor 32 on the tip firm, but also makes the conduction between the second lightning receptor 32 and the down-lead structure 2 smooth.

[0105] In the forming method of the blade with a lightning protection system, since the blade body 1 and the down-lead structure 2 are integrally formed, the second lightning receptor 32 is at the tip of the integrally formed structure and is electrically connected to the down-lead structure 2, making the setting of the down-lead structure 2 and the second lightning receptor 32 on the blade body 1 more efficient, which is beneficial to improving the forming efficiency of the blade with a lightning protection system.

[0106] Some embodiments of the present application also provide another forming method of a blade with a lightning protection system. The forming method of the blade with a lightning protection system is used to form the blade with a lightning protection system provided by the above technical solution, as Figure 6 shown. The forming method of the blade with a lightning protection system includes the following steps:

[0107] S1. Provide the blade body 1, and the blade body 1 includes a thermoplastic resin.

[0108] Since the blade body 1 provided in the above step S1 includes a thermoplastic resin, the blade body 1 can be secondarily melted and secondarily cured after being heated, which is convenient for reprocessing the blade body 1 to form a blade with a lightning protection system.

[0109] In some embodiments, the thermoplastic resin includes, but is not limited to, polymethyl methacrylate, polybutylene terephthalate, polyethylene, polyvinyl chloride, polystyrene, polyamide, polyoxymethylene, polycarbonate, polyphenylene ether, polysulfone, rubber. Those skilled in the art can select the type of thermoplastic resin according to the actual situation, so that the thermoplastic resin has the properties of softening when heated and hardening when cooled, and has good mechanical properties after curing.

[0110] S2. Provide a downlead structure 2 and a second lightning receptor 32, lay the downlead structure 2 and the second lightning receptor 32 on the blade body 1, and electrically connect the downlead structure 2 and the second lightning receptor 32.

[0111] Through the above step S2, both the downlead structure 2 and the second lightning receptor 32 are provided on the surface of the blade body 1, and the downlead structure 2 and the second lightning receptor 32 are electrically connected.

[0112] Specifically, the above step S2 may include: laying the downlead structure 2 at a preset position on the surface of the blade body 1, laying the second lightning receptor 32 at the tip of the blade body 1, and electrically connecting the downlead structure 2 and the second lightning receptor 32.

[0113] By laying the downlead structure 2 at a preset position on the surface of the blade body 1, the downlead structure 2 can be connected to a preset position on the surface of the blade body 1 after subsequent processing. By laying the second lightning receptor 32 at the tip of the blade body 1, the second lightning receptor 32 can be firmly connected to the tip of the blade body 1.

[0114] The electrical connection between the downlead structure 2 and the second lightning receptor 32 can be that the downlead structure 2 and the second lightning receptor 32 are connected together through a conductive member. Exemplarily, the conductive member can be a copper connecting rivet. The second lightning receptor 32 connected to the tip is connected to the downlead structure 2 through the conductive member, which not only makes the second lightning receptor 32 firmly connected to the downlead structure 2, but also makes the electrical conduction between the second lightning receptor 32 and the downlead structure 2 smooth.

[0115] S3. Provide a thermoplastic prepreg 4 and cover at least part of the downlead structure 2 with the thermoplastic prepreg 4.

[0116] Through the above step S3, at least part of the downlead structure 2 is covered by the thermoplastic prepreg 4, such as Figure 7As shown, at least part of the down-lead structure 2 is located between the blade body 1 and the thermoplastic prepreg 4, so that the thermoplastic prepreg 4 can be bonded to at least part of the down-lead structure 2. In some embodiments, the thermoplastic prepreg 4 also covers at least part of the joint between the down-lead structure 2 and the blade body 1, so that the thermoplastic prepreg 4 can enter the joint between the down-lead structure 2 and the blade body 1, and bond the down-lead structure 2 and the blade body 1 together.

[0117] In some embodiments, the material of the thermoplastic prepreg 4 can be the same as that of the blade body 1, both including thermoplastic resin, so that the thermoplastic prepreg 4 can undergo secondary melting and secondary curing, facilitating the thermoplastic prepreg 4 to melt and then coat at least part of the down-lead structure 2 and fill the gap between the down-lead structure 2 and the blade body 1, improving the connection strength of the down-lead structure 2 on the blade body 1.

[0118] In some embodiments, the forming method of the blade with a lightning protection system may further include the following steps:

[0119] S4. Pressurize the down-lead structure 2 and press the down-lead structure 2 against the blade body 1 with a preset pressure.

[0120] In the above step S4, by pressing the down-lead structure 2 against the blade body 1 with a preset pressure, the down-lead structure 2 can better contact the blade body 1, which is beneficial for the down-lead structure 2 to remelt the blade body 1.

[0121] Exemplarily, the preset pressure range for pressing the down-lead structure 2 against the blade body 1 can be from 100 psi to 200 psi, so that the down-lead structure 2 can sink into the blade body 1 after melting the blade body 1, which is beneficial for improving the connection firmness between the down-lead structure 2 and the blade body 1.

[0122] In some embodiments, the forming method of the blade with a lightning protection system may further include the following steps:

[0123] S5. Vacuum treatment, applying vacuum to the blade body 1 and the down-lead structure 2.

[0124] In the above step S4, by applying vacuum to the blade body 1 and the down-lead structure 2, the blade body 1 and the down-lead structure 2 are in a negative pressure environment, making the thermoplastic resin have better fluidity after melting, and the melted thermoplastic resin can better cover the down-lead structure 2 and fill the gap between the down-lead structure 2 and the blade body 1.

[0125] S6. Heat the down-lead structure 2, heating the down-lead structure 2 to melt the blade body 1, and the melted thermoplastic resin adheres to the down-lead structure 2.

[0126] Through the above step S6, the lead-down structure 2 can melt the blade body 1 and the thermoplastic prepreg 4 in contact therewith after being heated, so that the molten thermoplastic resin can fully contact the lead-down structure 2, and the molten thermoplastic resin can adhere to the surface of the lead-down structure 2 and coat the lead-down structure 2.

[0127] In some embodiments, the above step S6 includes:

[0128] Electrify the lead-down structure 2 to make the lead-down structure 2 generate heat, so that the lead-down structure 2 melts the thermoplastic prepreg 4 and the blade body 1, and both the molten thermoplastic resin and the blade body 1 adhere to the lead-down structure 2.

[0129] By electrifying the lead-down structure 2 provided on the blade body 1, the lead-down structure 2 generates heat, and the thermoplastic prepreg 4 and the blade body 1 in contact with the lead-down structure 2 will melt together. The molten thermoplastic resin will not only adhere to the lead-down structure 2, but also fill the gap between the lead-down structure 2 and the blade body 1 and coat at least part of the lead-down structure 2, so that the thermoplastic resin can firmly connect the lead-down structure 2 to the blade body 1 after curing.

[0130] In some embodiments, the molding method of the blade with a lightning protection system may further include the following steps:

[0131] S7. Cure the thermoplastic resin.

[0132] In the above step S7, the molten thermoplastic resin is cured again, so that the cured thermoplastic resin can firmly connect the lead-down structure 2 to the blade body 1. Since the second lightning arrester 32 is connected to the lead-down structure 2 through a conductive member, the second lightning arrester 32 is also connected to the blade body 1 along with the lead-down structure 2, and finally a blade with a lightning protection system is formed.

[0133] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application, and they should all be covered by the scope of the claims and the description of the present application. In particular, as long as there is no structural conflict, the technical features mentioned in each embodiment can be combined in any way. The present application is not limited to the specific embodiments disclosed in the text, but includes all technical solutions falling within the scope of the claims.

Claims

1. A forming method of a blade with a lightning protection system, characterized in that, it includes a blade with a lightning protection system, comprising: a blade body; a down-lead structure attached to the surface of the blade body; a lightning receiving assembly, the lightning receiving assembly includes a first lightning receiving member and a second lightning receiving member arranged separately, the first lightning receiving member is connected to the down-lead structure and exposed on the surface of the blade body, and the second lightning receiving member is arranged at the tip of the blade body and connected to the down-lead structure through a conductive member; The forming method of the blade with a lightning protection system includes: providing a blade body, the blade body includes a thermoplastic resin; arranging a down-lead structure and a second lightning receiving member, laying the down-lead structure and the second lightning receiving member on the blade body, and electrically connecting the down-lead structure and the second lightning receiving member; heating the down-lead structure, heating the down-lead structure to melt the blade body, and the molten thermoplastic resin adheres to the down-lead structure.

2. The forming method of the blade with a lightning protection system according to claim 1, characterized in that, before the step of heating the down-lead structure, it further includes: arranging a thermoplastic prepreg, covering at least part of the down-lead structure with the thermoplastic prepreg.

3. The forming method of the blade with a lightning protection system according to claim 2, characterized in that, the step of heating the down-lead structure includes: energizing the down-lead structure to make it generate heat, so that the down-lead structure melts the thermoplastic prepreg and the blade body, and the molten thermoplastic resin and the blade body both adhere to the down-lead structure.

4. The forming method of the blade with a lightning protection system according to claim 1, characterized in that, the step of arranging the down-lead structure and the second lightning receiving member includes: laying the down-lead structure at a preset position on the surface of the blade body, laying the second lightning receiving member at the tip of the blade body, and electrically connecting the down-lead structure and the second lightning receiving member.

5. The forming method of the blade with a lightning protection system according to claim 1, characterized in that, before the step of heating the down-lead structure, it further includes: pressurizing the down-lead structure, pressing the down-lead structure against the blade body with a preset pressure.

6. The forming method of the blade with a lightning protection system according to claim 1, characterized in that, before the step of heating the down-lead structure, it further includes: vacuum treatment, vacuum-packing the blade body and the down-lead structure.

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