Anti-icing coating for fan blade in high-altitude and high-cold areas, preparation process and application

Abstract

The invention provides an anti-icing coating for fan blades in high altitude and alpine regions and a preparation method and application thereof.The anti-icing coating is prepared from, by mass, 55-75 parts of resin matrix, 30-50 parts of functional filler and 12-19 parts of auxiliary additive, the resin matrix is prepared from organic silicon modified epoxy resin and waterborne polyurethane; the functional filler comprises a hydrophobic wear-resistant material, a phase change heat storage material and a conductive photo-thermal material; the auxiliary additive comprises a self-repairing agent and an anti-aging agent; cooperative anti-icing is achieved through the multi-stage material composite design and the gradient structure design, meanwhile, vibration generated when the fan blade rotates in the low-temperature environment can be resisted, the probability of paint face cracking is reduced, the effects of the functional filler and the auxiliary additive are combined, and the anti-icing effect of the fan blade is improved. And the paint surface on the fan blade can be self-repaired when micro cracks appear, so that the anti-icing effect is realized, and meanwhile, the cracking probability of the coating of the fan blade is also reduced.

Description

Technical Field

[0001] This invention belongs to the field of coating technology, and particularly relates to anti-icing coatings for wind turbine blades in high-altitude and cold regions, their preparation process, and applications. Background Technology

[0002] Anti-icing coatings for wind turbine blades are a key means of addressing blade icing problems by utilizing material surface modification technology. Through different mechanisms such as superhydrophobicity, photothermal conversion, electrothermal conversion, or reduction of ice adhesion strength, they aim to delay icing, reduce ice adhesion, or actively melt ice to mitigate the damage caused by icing and ensure the safe and efficient operation of wind turbines. Currently, research on superhydrophobic coatings and low-ice adhesion coatings is active in passive anti-icing, while electrothermal coatings are relatively mature in active de-icing but face energy consumption challenges. Durability, environmental adaptability, and cost-effectiveness remain directions for continuous optimization for all types of coatings. In practical applications, different anti-icing strategies often need to be selected or combined based on the specific climatic conditions of the wind farm, economic considerations, and technological maturity.

[0003] While existing wind turbine blade coatings can withstand low-temperature environments, the vibrations generated by the rotating blades in high-altitude and frigid regions, combined with the reduced toughness of the coating and blades in low-temperature environments, make the coating on wind turbine blades very prone to cracking under multiple factors, thus requiring improvement. Summary of the Invention

[0004] The purpose of this invention is to provide an anti-icing coating for wind turbine blades in high-altitude and cold regions, its preparation process, and its application, thereby solving the defect that existing wind turbine blade coatings are prone to cracking in high-altitude and cold regions.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: In a first aspect, the anti-icing coating for wind turbine blades in high-altitude and cold regions provided by the present invention comprises, by weight, 55-75 parts of resin matrix, 30-50 parts of functional filler, and 12-19 parts of auxiliary additives, wherein the resin matrix comprises silicone-modified epoxy resin and waterborne polyurethane; the functional filler comprises hydrophobic and wear-resistant materials, phase change heat storage materials, and conductive photothermal materials; and the auxiliary additives comprise self-healing agents and anti-aging agents.

[0006] Preferably, the resin matrix comprises 35-45 parts of silicone-modified epoxy resin and 20-30 parts of waterborne polyurethane by mass fraction.

[0007] Preferably, the functional filler comprises, by mass fraction, 15-25 parts of hydrophobic and wear-resistant material, 10-15 parts of phase change heat storage material, and 5-10 parts of conductive and photothermal material.

[0008] Preferably, the hydrophobic and wear-resistant material comprises nano-silica and polytetrafluoroethylene.

[0009] Preferably, the phase change thermal storage material includes dipotassium hydrogen phosphate hexahydrate and polymethyl methacrylate.

[0010] Preferably, the conductive photothermal material includes MXene and ferric chloride hexahydrate.

[0011] Preferably, by weight, the auxiliary additives include 3-5 parts of silicone oil microcapsules, 1-2 parts of benzotriazole UV absorber, and 8-12 parts of water-based isocyanate curing agent.

[0012] Secondly, the method for preparing an anti-icing coating for wind turbine blades in high-altitude and cold regions provided by the present invention includes the following steps: Weigh out 55-75 parts of resin matrix, 30-50 parts of functional filler and 12-19 parts of auxiliary additives by mass fraction. Organosilicon-modified epoxy resin and waterborne polyurethane are mixed and then waterborne isocyanate curing agent is added and stirred and dispersed. After mixing evenly, phase change heat storage material is added and stirred evenly under low-speed stirring conditions. Then, hydrophobic wear-resistant material is added and stirred evenly under high-speed stirring conditions. Conductive photothermal material is added and ultrasonically dispersed evenly under ultrasonic conditions. After being evenly dispersed, auxiliary additives and defoamers are added, and the mixture is stirred evenly under negative pressure to obtain an anti-icing coating.

[0013] Thirdly, the present invention provides an anti-icing wind turbine blade for use in high-altitude and cold regions, wherein the wind turbine blade is coated with the aforementioned anti-icing coating.

[0014] Fourthly, the present invention provides a method for preparing anti-icing wind turbine blades for use in high-altitude and cold regions, comprising the following steps: The wind turbine blades to be processed are pre-treated to obtain pre-treated wind turbine blades; The coating is sprayed onto the surface of the pretreated wind turbine blades to obtain anti-icing wind turbine blades for use in high-altitude and cold regions.

[0015] Compared with the prior art, the beneficial effects of the present invention are: The anti-icing coating for wind turbine blades in high-altitude and frigid regions provided by this invention, through the synergistic effect of organosilicon-modified epoxy resin and waterborne polyurethane in the resin matrix, endows the coating with excellent adhesion, flexibility, and low-temperature impact resistance, effectively resisting the coating cracking problem caused by vibration and temperature difference changes in low-temperature and frigid environments. The hydrophobic and wear-resistant materials, phase change heat storage materials, and conductive photothermal materials in the functional fillers form a multi-mechanism synergistic anti-icing system. Among them, the hydrophobic and wear-resistant materials improve the surface hydrophobicity and delay icing, the phase change heat storage materials store and release heat through the phase change process to mitigate temperature fluctuations, and the conductive photothermal materials achieve dual active de-icing through photothermal and electrothermal processes. This coating significantly enhances its anti-icing performance and adaptability in extreme environments. The self-healing agent in the auxiliary additives can self-repair when micro-cracks appear in the coating, while the anti-aging agent effectively inhibits UV radiation and environmental aging, further enhancing the coating's durability and long-term service stability. The coating employs a multi-level composite and gradient structure design, achieving not only multi-functional integration of anti-icing, wear resistance, weather resistance, and self-healing, but also ensuring compatibility and synergistic effects among materials through optimized component ratios and preparation processes. This provides a comprehensive anti-icing coating solution for wind turbine blades in high-altitude and cold regions, offering outstanding performance, strong environmental adaptability, and long service life.

[0016] Furthermore, by using nano-silica and polytetrafluoroethylene in the designed functional fillers, the agglomeration of the coating can be reduced, and the hydrophobicity and resin compatibility of the coating can be improved. In addition, the microcapsule morphology of the phase change heat storage material can enhance the thermal cycling stability of the coating.

[0017] Furthermore, conductive photothermal materials synthesized from MXene and iron oxide using a hydrothermal method can enhance the photothermal stability of coatings.

[0018] Furthermore, the designed auxiliary additives enable the paint surface of the wind turbine blades to have a self-healing function, and enhance the aging effect by quenching excited-state molecules. Through multi-level material composite design and gradient structure design, synergistic anti-icing is achieved, while also resisting the vibration generated when the wind turbine blades rotate in low-temperature environments, reducing the probability of paint cracking. In addition, combined with the effects of functional fillers and auxiliary additives, the paint surface on the wind turbine blades can self-repair when micro-cracks appear, and has a photothermal conversion function to achieve an active ice melting effect. Meanwhile, interlayer aminosilane crosslinking and plasma activation greatly enhance the adhesion of the paint surface.

[0019] In summary, this invention achieves synergistic anti-icing through multi-level material composite design and gradient structure design, while also resisting the vibration generated when the wind turbine blades rotate in low-temperature environments, reducing the probability of paint cracking. Furthermore, combined with the effects of functional fillers and auxiliary additives, the paint surface on the wind turbine blades can self-repair when micro-cracks appear, thus achieving anti-icing effect while reducing the probability of wind turbine blade coating cracking. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the process involved in an embodiment of the present invention. Detailed Implementation

[0021] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0022] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.

[0023] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0024] As used in this application specification and the appended claims, the term "if" may be interpreted, depending on the context, as "when," "once," "in response to determination," or "in response to detection." Similarly, the phrase "if determined" or "if detected [the described condition or event]" may be interpreted, depending on the context, as meaning "once determined," "in response to determination," "once detected [the described condition or event]," or "in response to detection [the described condition or event]."

[0025] Furthermore, in the description of this application and the appended claims, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0026] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0027] Example 1 The anti-icing coating for wind turbine blades in high-altitude and cold regions provided in this embodiment includes: The resin matrix is ​​made of a composite of silicone-modified epoxy resin and waterborne polyurethane; The functional filler is made of a composite of hydrophobic and wear-resistant materials, phase change heat storage materials and conductive and photothermal materials. The auxiliary additive is composed of a self-healing agent and an anti-aging agent. The mass ratio of the resin matrix, functional filler and auxiliary additives is: 55-75 parts resin matrix, 30-50 parts functional filler and 12-19 parts auxiliary additives.

[0028] Example 2 Based on Example 1, the anti-icing coating for wind turbine blades in high-altitude and cold regions provided in this example comprises, by weight, 35-45 parts of silicone-modified epoxy resin and 20-30 parts of waterborne polyurethane as the resin matrix.

[0029] Example 3 Based on Example 1, the anti-icing coating for wind turbine blades in high-altitude and cold regions provided in this example, by weight, includes 15-25 parts of hydrophobic and wear-resistant material, 10-15 parts of phase change heat storage material, and 5-10 parts of conductive photothermal material.

[0030] The hydrophobic and wear-resistant material comprises nano-silica and polytetrafluoroethylene (PTFE), with a mass ratio of nano-silica to PTFE of 3:1. This design allows the hydrophobic and wear-resistant material to maintain excellent hydrophobicity while utilizing nano-silica to improve the dispersion of fillers in the resin matrix, and to utilize PTFE to reduce the coefficient of friction and improve wear resistance.

[0031] The phase change thermal storage material includes dipotassium hydrogen phosphate hexahydrate and polymethyl methacrylate, with a mass ratio of dipotassium hydrogen phosphate hexahydrate to polymethyl methacrylate of 3:1. This design ensures that the phase change thermal storage material has sufficient thermal storage capacity, while forming a complete and stable microcapsule wall structure to prevent leakage of the phase change thermal storage material.

[0032] The conductive photothermal material includes MXene and ferric chloride hexahydrate, with a molar ratio of MXene to ferric chloride hexahydrate of 1:2.

[0033] Example 4 Based on Example 1, the anti-icing coating for wind turbine blades in high-altitude and cold regions provided in this example includes, by weight, 3-5 parts of silicone oil microcapsules, 1-2 parts of benzotriazole UV absorber and 8-12 parts of water-based isocyanate curing agent.

[0034] Example 5 The preparation process of the anti-icing coating for wind turbine blades in high-altitude and cold regions provided in this embodiment includes the following steps: S1. Substrate pretreatment: Clean the surface of the wind turbine blades and perform plasma activation, then apply a primer to the wind turbine blades. S2. Coating preparation: First, prepare the functional filler, then mix the resin matrix, then disperse the functional filler into the resin matrix, and finally add auxiliary additives and defoamers to the mixture of resin matrix and functional filler. S3. Coating and Curing: Apply the coating to the surface of the fan blades according to the defined gradient; S4. Post-treatment: Micro-nano structures are constructed on the paint surface using laser etching, and the hydrophobic effect is enhanced by spraying a fluorosilane solution diluted with 1%~3% ethanol. Specifically: A nanosecond pulsed laser with a wavelength of 1064 nm was used to scan and etch the surface of the sprayed and cured coating. The laser power was set to 10~30W, the scanning speed was set to 100~500mm / s, and the scanning spacing was set to 20~50μm to construct a composite hydrophobic surface with micron-level protrusions and nano-level roughness. Then, a solution of heptadecafluorodecyltrimethoxysilane diluted with 1%~3% ethanol was sprayed and cured and crosslinked at 80~100℃ for 30~60 minutes to reduce the surface energy and enhance the hydrophobic effect.

[0035] Example 6 Based on Example 5, this example provides a preparation process for anti-icing coatings for wind turbine blades in high-altitude and cold regions. In step S1, the surface of the wind turbine blades is wiped with anhydrous ethanol, then treated with atmospheric pressure plasma, then sprayed with polyaspartic acid ester primer, and cured at room temperature for 1 hour.

[0036] In step S2, the specific process for preparing the functional filler is as follows: Preparation of the hydrophobic wear-resistant material: First, nano-silica is impregnated with a 5% (w / w) aminosilane ethanol solution and reacted at 60°C for 2 hours. Then, polytetrafluoroethylene is treated with perfluorooctyltriethoxysilane to further enhance the hydrophobicity of polytetrafluoroethylene and give its surface reactive functional groups. Then, the treated nano-silica and polytetrafluoroethylene are mixed in a ratio of 3:1 by ball milling. This composite method forms a hydrophobic wear-resistant system with synergistic effect. Preparation of the conductive photothermal material: Ferric chloride hexahydrate was added to the MXene dispersion at a molar ratio of 1:2, and then a hydrothermal reaction was carried out at 180°C for 8 hours to generate iron oxide nanoparticles to anchor the MXene sheets. Argon gas was then used for drying and protection. Using the in-situ hydrothermal synthesis method, iron oxide nanoparticles were firmly grown on the MXene sheets, forming a stable heterojunction structure, which improved the photothermal conversion efficiency and electrothermal stability. The phase change thermal storage material was prepared by using dipotassium hydrogen phosphate hexahydrate and polymethyl methacrylate in a mass ratio of 3:1. Dipotassium hydrogen phosphate hexahydrate was used as the core material and polymethyl methacrylate as the wall material. The phase change thermal storage material was prepared into microcapsules with a particle size of 20-50 micrometers by emulsion polymerization at 75°C and pH=4.5. This preparation method ensures the sealing integrity and thermal stability of the phase change microcapsules under thermal cycling in cold regions.

[0037] In step S2, the specific process of mixing the resin matrix, functional filler, auxiliary additives, and defoamer is as follows: Preparation of resin matrix: Silicone-modified epoxy resin and waterborne polyurethane were mixed in a ratio of 2:1, and after adding waterborne isocyanate curing agent, the mixture was dispersed at 2000 rpm for 30 minutes. Mixing of functional fillers: Add phase change heat storage material at 500 rpm and stir for 30 minutes. Then increase the speed to 1500 rpm, add hydrophobic and wear-resistant material and stir for 40 minutes. Then add conductive photothermal material under ultrasonic conditions of 40 kHz and 600 W and ultrasonically disperse for 30 minutes. Mixing of auxiliary additives and defoamers: Add auxiliary additives and defoamers, and stir for 30 minutes at -0.08 MPa.

[0038] In step S3, the spray gun parameters are set to a spray distance of 250 mm, a pressure of 0.4 MPa, and a moving speed of 2.0 m / min. The spraying is carried out according to the preset gradient of the base layer, intermediate layer, and top layer. After the base layer is sprayed, a 0.5 wt% aminosilane ethanol solution is sprayed before it is cured. Then the intermediate layer is sprayed. After the intermediate layer is sprayed, the surface of the intermediate layer is treated with 50 W plasma. Finally, the top layer is sprayed.

[0039] In this embodiment, the siloxane segments in the silicone-modified epoxy resin can improve the flexibility of the resin matrix, the epoxy can provide adhesion, the carboxyl groups of the waterborne polyurethane can impart water dispersibility to the resin matrix, and the urethane bonds can enhance the wear resistance of the resin matrix. The combination of silicone-modified epoxy resin and waterborne polyurethane can form a silicone-polyurethane interpenetrating network, which improves the overall low-temperature impact resistance of the coating composed of the resin matrix. The hydrophobic and wear-resistant material is made of nano-silica and polytetrafluoroethylene. The hydrophobic and wear-resistant material made of nano-silica and polytetrafluoroethylene can improve the hydrophobicity and resin compatibility of the coating and reduce the agglomeration of the coating.

[0040] The phase change thermal storage material is made of dipotassium hydrogen phosphate hexahydrate and polymethyl methacrylate, with dipotassium hydrogen phosphate hexahydrate as the core material and polymethyl methacrylate as the wall material, which allows the phase change thermal storage material to be prepared in the form of microcapsules, thereby improving the thermal cycling stability of the coating. The conductive photothermal material is prepared by hydrothermal synthesis of MXene and iron oxide, which can enhance the photothermal stability of the coating. The silicone oil microcapsules can be composed of melamine-formaldehyde resin as the wall material to encapsulate hydroxyl silicone oil. When microcracks appear on the paint surface, the capsules rupture under stress, releasing silicone oil to repair the microcracks. The anti-aging agent is made of benzotriazole UV absorbers, which can quench excited-state molecules. The curing of the silicone oil microcapsules and benzotriazole UV absorbers is completed by an aqueous isocyanate curing agent.

[0041] In this embodiment, the addition of silicone-modified epoxy resin gives the resin matrix good adhesion and flexibility, and the addition of waterborne polyurethane gives the resin matrix good wear resistance and water dispersibility. The silicone-polyurethane interpenetrating network formed by the combination of the two can improve the overall low-temperature impact resistance of the coating, so that when the coating is sprayed on the wind turbine blades, it has resistance to the vibration generated by the rotation of the wind turbine blades and the low temperature, reducing the probability of cracking of the paint surface after coating. Furthermore, the use of nano-silica and polytetrafluoroethylene in the designed functional fillers reduces coating agglomeration and improves the hydrophobicity and resin compatibility of the coating. The microcapsule form of the box-type thermal storage material can enhance the thermal cycling stability of the coating, while the conductive photothermal material prepared by hydrothermal synthesis of MXene and iron oxide can enhance the photothermal stability of the coating. In addition, the designed auxiliary additives can enable the paint surface of the wind turbine blades to have a self-healing function, and enhance the aging effect by quenching excited-state molecules.

[0042] In this embodiment, the multi-level material composite design and gradient structure design achieve synergistic anti-icing while resisting the vibration generated when the wind turbine blades rotate in low-temperature environments, reducing the probability of paint cracking. Furthermore, the combined effects of functional fillers and auxiliary additives enable the paint on the wind turbine blades to self-repair when micro-cracks appear, and it also has a photothermal conversion function to achieve an active ice-melting effect. Meanwhile, interlayer aminosilane crosslinking and plasma activation greatly enhance the adhesion of the paint surface.

[0043] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. An anti-icing coating for wind turbine blades used in high-altitude and cold regions, characterized in that, The product comprises, by weight, 55-75 parts of resin matrix, 30-50 parts of functional filler, and 12-19 parts of auxiliary additives. The resin matrix comprises silicone-modified epoxy resin and waterborne polyurethane. The functional filler comprises hydrophobic and wear-resistant materials, phase change heat storage materials, and conductive photothermal materials. The auxiliary additives comprise self-healing agents and anti-aging agents.

2. The anti-icing coating for wind turbine blades in high-altitude and cold regions according to claim 1, characterized in that, The resin matrix comprises, by mass fraction, 35-45 parts of silicone-modified epoxy resin and 20-30 parts of waterborne polyurethane.

3. The anti-icing coating for wind turbine blades in high-altitude and cold regions according to claim 1, characterized in that, The functional filler comprises, by mass fraction, 15-25 parts of hydrophobic and wear-resistant material, 10-15 parts of phase change heat storage material, and 5-10 parts of conductive and photothermal material.

4. The anti-icing coating for wind turbine blades in high-altitude and cold regions according to claim 3, characterized in that, The hydrophobic and wear-resistant material includes nano-silica and polytetrafluoroethylene.

5. The anti-icing coating for wind turbine blades in high-altitude and cold regions according to claim 3, characterized in that, The phase change thermal storage material includes dipotassium hydrogen phosphate hexahydrate and polymethyl methacrylate.

6. The anti-icing coating for wind turbine blades in high-altitude and cold regions according to claim 3, characterized in that, The conductive photothermal material includes MXene and ferric chloride hexahydrate.

7. The anti-icing coating for wind turbine blades in high-altitude and cold regions according to claim 3, characterized in that, The auxiliary additives, by weight, include 3-5 parts of silicone oil microcapsules, 1-2 parts of benzotriazole UV absorber, and 8-12 parts of water-based isocyanate curing agent.

8. A method for preparing an anti-icing coating for wind turbine blades used in high-altitude and cold regions, characterized in that, Includes the following steps: Weigh out 55-75 parts of resin matrix, 30-50 parts of functional filler and 12-19 parts of auxiliary additives by mass fraction. Organosilicon-modified epoxy resin and waterborne polyurethane are mixed and then waterborne isocyanate curing agent is added and stirred and dispersed. After mixing evenly, phase change heat storage material is added and stirred evenly under low-speed stirring conditions. Then, hydrophobic wear-resistant material is added and stirred evenly under high-speed stirring conditions. Conductive photothermal material is added and ultrasonically dispersed evenly under ultrasonic conditions. After being evenly dispersed, auxiliary additives and defoamers are added, and the mixture is stirred evenly under negative pressure to obtain an anti-icing coating.

9. An anti-icing wind turbine blade for use in high-altitude and cold regions, characterized in that, The wind turbine blades are coated with the anti-icing coating as described in claim 1.

10. A method for preparing anti-icing wind turbine blades for use in high-altitude and cold regions, characterized in that, Includes the following steps: The wind turbine blades to be processed are pre-treated to obtain pre-treated wind turbine blades; The coating described in claim 1 is sprayed onto the surface of the pretreated wind turbine blades to obtain anti-icing wind turbine blades for use in high-altitude and cold regions.

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